Custom Coffered Surface Layout, Fabrication, and Installation Methods and Processes

Abstract

Systems and methods are disclosed for providing coffered ceilings with a plurality of preassembled coffered modules, each of which includes a ceiling panel precut in accordance with an order; cutting beam wall boards in accordance with the order, wherein the beam wall boards are attached to the ceiling panel and extend away from the ceiling panel; and a beam wall molding custom-fitted inside the beam wall boards. Automated systems to receive and fabricate custom coffered module orders upon payment are also disclosed.

What is claimed is: 
     
         1 . A method to form a preassembled coffered module, comprising:
 fabricating a ceiling panel to a pre-determined size;   attaching beam wall boards perpendicular to the ceiling panel;   installing beam wall moldings inside of the beam wall boards after they have been attached to the ceiling panel;   wherein the coffer beam wall board placement on the ceiling board defines a predetermined size flange around the perimeter of the module for use in fastening to the substrate as well as for proper spacing between other modules during the on-site installation process;   
     
     
         2 . The method of claim  11 , wherein the coffer beam wall boards are attached using a joinery process. 
     
     
         3 . The method of claim  11 , comprising joining the beam wall boards to one another where they meet during preassembly. 
     
     
         4 . The method of claim  11 , comprising:
 cutting the beam wall moldings to specified lengths and butting, mitering or coping them on the ends where they meet to one another.   
     
     
         5 . The method of claim  11 , comprising:
 aligning and joining of the beam wall boards to the ceiling panel during the preassembly process.   
     
     
         6 . The method of claim  15 , comprising:
 applying glue or adhesive to the edge of each beam wall board that meets with the face of the ceiling panel and using a dado groove in the face of the ceiling panel as a guide for proper placement, positioning and fastening of the beam wall board to the ceiling panel.   
     
     
         7 . The method of claim  11 , comprising:
 completing the modules by installing the beam board moldings one at a time in either clockwise or counter clockwise sequence inside of a completed panel and beam wall board assembly.   
     
     
         8 . The method of claim  11 , comprising:
 installing the coffer module, further comprising:   locating and marking centers of a length and a width of a ceiling or surface area;   locating and marking of the underlying framing joists or structural members of the surface area for secure fastening of the coffer modules;   installing the coffer modules using shim screws;   trimming the length of and installing the intersecting beam bottom boards;   trimming the length and width of and installing the outer perimeter beam bottom boards; and;   trimming length of and installing the perimeter moldings.   
     
     
         9 . The method of claim  11 , comprising:
 fabricating the coffered module components without preassembly and unfinished, without preassembly and prefinished, preassembled and unfinished, or preassembled and prefinished.   
     
     
         10 . A method to form a custom sized coffered module in accordance with a customer's order, comprising:
 receiving the customer's order for coffered modules with a predetermined size and with options selected from a group consisting of: without preassembly and unfinished, without preassembly and prefinished, preassembled and unfinished, or preassembled and prefinished;   fabricating a ceiling panel to the predetermined size;   fabricating coffer beam wall boards to be attached to the ceiling panel, wherein the coffer beam wall board placement defines a predetermined size flange around the perimeter of the module for fastening to the substrate as well as for proper spacing between other modules during an on-site installation process;   cutting of the beam wall moldings to be fitted inside of the completed ceiling panel and beam wall board assemblies; and   shipping the completed preassembled coffer modules for on-site installation or shipping the coffer module components unassembled for on-site preassembly and installation.