A pre-fabricated integrated electrical box assembly and method of use

Abstract

A prefabricated integrated electrical box component and its usage method relate to the field of building embedded conduit construction technology. The component includes a prefabricated concrete component, a horizontal steel base, vertical steel embedded inside the prefabricated concrete component, an electrical box embedded inside the prefabricated concrete component, embedded down-line conduits inside the prefabricated concrete component, embedded up-line conduits inside the prefabricated concrete component, and a grounding wire embedded inside the prefabricated concrete component connecting the electrical box and the vertical steel. Compared with existing technologies, this invention has the advantages of: pre-reserved cable outlets are less prone to damage; it avoids deviations from the actual wall position, ensuring smooth vertical pipe connection; it eliminates the need for grooving the masonry to ensure structural safety; it ensures the box is firmly fixed; it prevents cracking and hollowing around the box; it prevents pipe blockage; it ensures that grounding and fireproof sealing are not overlooked; it guarantees electrical safety and fire prevention; and it ensures on-site construction accuracy.

Description

Technical Field

[0001] This invention relates to the field of building pre-embedded conduit construction technology, and in particular to prefabricated integrated electrical box components and their usage methods. Background Technology

[0002] In the pre-embedded construction of electrical engineering in building construction, regardless of whether a precast concrete slab or cast-in-place structure is used, the traditional process typically follows the technical route of "one-time pre-embedding in the main structure and secondary piping in the later stage." This process requires laying horizontal conduits within the floor slab during the main structure construction phase, reserving vertical outlets upwards and downwards. The conduit openings are exposed at the structural edges and require semi-finished protection. Later, during the masonry construction phase, the vertical conduits are connected to the reserved outlets one by one through overlapping procedures or secondary slotting after masonry completion, and then connected to the distribution box or switch socket. The entire process involves multiple steps, including pre-positioning, masonry slotting, conduit installation, and slot filling. It involves many steps and interfaces, is time-consuming, and requires significant coordination, making the construction process quite complex and demanding high precision in on-site management and seamless workflow.

[0003] Due to the complexity of the aforementioned processes, various quality problems can easily arise during actual construction, directly affecting project quality and structural safety. Firstly, at the junction of the main structure and masonry, the reserved cable outlets are easily damaged due to inadequate protection of semi-finished products, or there may be deviations from the actual position of the wall, leading to uneven connection of vertical pipes and potential hazards such as "pipe breakage" or inability to connect. Secondly, during masonry grooving, excessively wide or long grooves and violent chiseling are common. Grooves that are too deep will excessively weaken the wall cross-section and affect structural safety, while grooves that are too shallow will result in insufficient pipe wall protection. Furthermore, problems such as mismatch between box and groove dimensions and insecure fixing are also prominent. Thirdly, during filling and plastering, the mesh filling is difficult to compact and is not in place, easily causing cracks and hollow areas along the pipes and around the boxes, affecting the finishing quality. Fourthly, at pipe joints, inadequate sealing of pipe openings or weak bonding of joints can easily cause blockages. Grounding and fireproofing sealing are often overlooked, posing safety hazards to buried electrical equipment and fire prevention. It is evident that the complexity of traditional processes and their dependence on on-site construction precision have become key factors restricting the quality of electrical pre-embedded engineering.

[0004] Patent CN2021225491099 discloses a prefabricated block for an indoor electrical box, including an electrical box body with side wall openings. A prefabricated block is fixedly fitted onto the outer wall of the electrical box body, and wiring steel pipes that communicate with the interior of the electrical box and penetrate the prefabricated block are fixedly installed at the top and bottom of the electrical box. This patented technology only solves the problem of slotting the electrical box installation groove and does not solve other problems of existing technologies.

[0005] Patent CN2022207487193 discloses a prefabricated wall panel without perforation, comprising prefabricated electrical box blocks, Type I prefabricated pipeline connection blocks, Type II prefabricated pipeline connection blocks, and ordinary building blocks. An electrical box is pre-embedded within the prefabricated electrical box block, connected to a flame-retardant flexible conduit, the end of which extends beyond the side of the prefabricated electrical box block. A flame-retardant flexible conduit and a pre-installed sleeve are pre-embedded within the Type I prefabricated pipeline connection block, and they are joined together within the block. The end of the pre-installed sleeve is located on one side of a small area of ​​the Type I prefabricated pipeline connection block, with the end of the flame-retardant flexible conduit extending to the opposite side. The Type II prefabricated pipeline connection block has the same structure as the Type I prefabricated pipeline connection block. The difference lies in that the reserved sleeve port within the Type II prefabricated conduit connection block is located on one side of a large area of ​​the Type II prefabricated conduit connection block, and the end of the flame-retardant flexible conduit within the Type II prefabricated conduit connection block extends to the opposite side. In the composite wall, the prefabricated electrical box block is adjacent to either the Type I or Type II prefabricated conduit connection block, and vice versa. The flame-retardant flexible conduit on the prefabricated electrical box block, Type I prefabricated conduit connection block, or Type II prefabricated conduit connection block is aligned with the reserved sleeve port, and the end of the flame-retardant flexible conduit is inserted into the reserved sleeve and connected end-to-end with the flame-retardant flexible conduit inside the block, thus forming a wiring conduit embedded in the composite wall to connect to the electrical box. This patented technology only solves the problem of grooving the wire trough and does not solve other problems of existing technologies. Summary of the Invention

[0006] This invention aims to provide a technical solution that overcomes one or more of the above-mentioned shortcomings. When the main body is connected to the masonry, the reserved outlet is not easily damaged, there will be no deviation from the actual position of the wall, ensuring smooth connection of the vertical pipe, eliminating the need to groove the masonry, ensuring structural safety, ensuring that the box is firmly fixed, preventing cracks and hollows around the box, preventing pipe blockage, ensuring that grounding and fireproof sealing are not missed, ensuring electrical safety and no fire hazards, and ensuring the accuracy of on-site construction. This invention relates to a prefabricated integrated electrical box component and its usage method.

[0007] The prefabricated integrated electrical box component of this invention is implemented as follows: it includes a prefabricated concrete component, a steel horizontal base, a vertical steel section embedded inside the prefabricated concrete component, an electrical box embedded inside the prefabricated concrete component, a pre-embedded down-line conduit embedded inside the prefabricated concrete component, a pre-embedded up-line conduit embedded inside the prefabricated concrete component, and a grounding wire embedded inside the prefabricated concrete component connecting the electrical box and the vertical steel section. The electrical box is positioned between the pre-embedded down-line conduit and the pre-embedded up-line conduit, and the inner cavity of the electrical box is connected to the pipe holes of the pre-embedded down-line conduit and the pre-embedded up-line conduit. The steel horizontal base is positioned below the prefabricated concrete component, and the lower end of the vertical steel section extending outside the lower end of the prefabricated concrete component is fixed to the steel horizontal base.

[0008] Preferably, the precast concrete component has toothed joints on both sides, which can form an I-shaped joint with the surrounding masonry to satisfy the interlocking force between the masonry and the precast integrated electrical box component.

[0009] Preferably, an identification electronic tag is embedded inside the precast concrete component.

[0010] The method of using the prefabricated integrated electrical box component of this invention is implemented as follows, including the following steps: S1: When manufacturing prefabricated integrated electrical box components, the prefabricated integrated electrical box components are manufactured and the building information is entered at a site outside the construction site, and then transported to the construction site for installation when the construction node arrives. S2: During the building structure construction phase, prefabricated integrated electrical box components are transported to the construction site that matches the building information in advance. After the floor slab structure formwork is completed, a tower crane is used to lift the prefabricated integrated electrical box components to the installation position and install and fix them on the floor slab structure formwork. After the building information is calibrated and accepted, the floor slab structure reinforcement construction begins. The floor slab structure reinforcement is welded to the steel horizontal base to form a whole, and then welded to the grounding system (the grounding system (also known as the grounding grid) refers to the general term for multiple metal grounding electrodes buried at a certain depth underground and connected by conductors to form a mesh structure of grounding bodies. It is widely used in the power, construction and communication industries and mainly undertakes the functions of safety protection and electromagnetic shielding. This system connects the casing or neutral point of electrical equipment to the earth to ensure that the current can be safely discharged in the event of a fault, prevent electric shock accidents and ensure stable operation of equipment). Then, horizontal conduits are pre-embedded in the floor slab structure. The horizontal conduits are connected to the lower end of the pre-embedded down conduits at the bottom of the prefabricated integrated electrical box components to complete the pre-embedded down conduits and horizontal conduits at this location. Then, the structural concrete is poured. S3: During the wall construction phase, the masonry around the prefabricated integrated electrical box component is built. The masonry is embedded into the toothed joint of the prefabricated integrated electrical box component, so that the prefabricated integrated electrical box component and the surrounding masonry form an interlocking joint.

[0011] Since S2 has been correctly positioned, the wall surface and the prefabricated integrated electrical box components are flat after this stage is completed; During the decoration construction phase, since the pre-embedded upward conduit, pre-embedded downward conduit, and horizontal conduit have already been installed in steps S1 and S2, no secondary piping is required in this phase. The wires can be directly threaded without the need for secondary wire groove cutting, and the wall structure will not be damaged.

[0012] The purpose of setting up a steel horizontal base is to ensure the stability of the prefabricated integrated electrical box components during installation, and to ensure that they will not overturn or shift due to various construction loads.

[0013] Preferably, the steel horizontal base includes two horizontally parallel steel bars and a horizontal brace connecting the two horizontal steel bars. The horizontal steel bars are one of I-beams, channel steel, and angle steel.

[0014] The vertical steel section is perpendicular to the horizontal steel base to ensure that the prefabricated integrated electrical box components are in a vertical position after installation, thus ensuring installation quality.

[0015] Preferably, the upper end of the pre-embedded downline conduit embedded inside the precast concrete component is connected to the electrical box, and the lower end is bent at 90 degrees to connect with the horizontal conduit pre-embedded in the construction layer, so as to connect with the horizontal conduit pre-embedded in the construction layer.

[0016] The pre-embedded overhead conduit embedded inside the precast concrete component has its lower end connected to the electrical box and its upper end connected to the upper layer structure, and its upper end connected to the pre-embedded horizontal conduit of the upper layer structure.

[0017] The pre-embedded downline conduit, electrical box, and pre-embedded upline conduit form a vertically continuous wiring channel, providing the necessary conditions for vertical cross-floor wiring.

[0018] The grounding wire embedded within the precast concrete component connects the electrical box and the vertical steel section. This ensures reliable grounding of the electrical box, and the grounding wire is a metal wire conforming to specifications. One end of the grounding wire connects to the electrical box, and the other end connects to the vertical steel section embedded within the precast concrete component. The grounding connection transmission path proceeds sequentially from the electrical box to the grounding wire, the vertical steel section, the horizontal steel base, the grounding system of the main structure, and finally to the ground.

[0019] The identification electronic tags embedded inside the precast concrete components are passive ultra-high frequency RFID electronic tags. The tags are embedded near the surface of the precast concrete components, encapsulated in modified polyurethane resin, and have an IP68 protection rating. Each tag stores a unique TID code and, during the production phase, includes the component number, production date, strength grade, project name, building, and unit. The tag's user storage area is read-write, used for installation verification during construction, and after delivery, allows property management or owners to trace component information and supplement maintenance records, achieving full lifecycle information traceability management. During construction, it is used for precise positioning and installation; after building delivery, it is used by property management or owners to trace component information and manage their assigned unit.

[0020] Compared with existing technologies, this invention has the advantages of preventing damage to the reserved outlet when the main body is connected to the masonry, ensuring that there is no deviation from the actual position of the wall, ensuring smooth connection of the vertical pipe, eliminating the need to groove the masonry, ensuring structural safety, ensuring that the box is firmly fixed, preventing cracks and hollows around the box, preventing pipe blockage, ensuring that grounding and fireproof sealing are not missed, ensuring the safety of buried power supply and eliminating fire hazards, and ensuring the accuracy of on-site construction. Attached Figure Description

[0021] Figure 1 This is a structural schematic diagram of the prefabricated integrated electrical box component of the present invention; Figure 2 This is an internal structural diagram of the prefabricated integrated electrical box component of the present invention; Figure 3 A schematic diagram illustrating the usage of prefabricated integrated electrical box components; Figure 4 This is a structural diagram of the floor after the concrete pouring is completed; Figure 5 for Figure 3 A magnified view of a portion of point A in the middle.

[0022] Explanation of reference numerals: 1-Precast concrete component; 101-Reinforcing steel; 2-Steel horizontal base; 201-Horizontal I-beam; 202-Horizontal brace; 3-Vertical steel; 301-Angle steel plate; 4-Electrical box; 5-Embedded downline conduit; 501-Straight pipe; 502-90-degree bend; 6-Embedded upline conduit; 7-Grounding wire; 8-Toothed joint structure; 9-Masonry; 10-Horizontal conduit; 11-Floor slab formwork; 12-Floor slab reinforcement; 13-Floor slab structure. Detailed Implementation

[0023] The prefabricated integrated electrical box component and its usage method of the present invention will now be described in further detail with reference to the accompanying drawings and embodiments: like Figure 1 , 2 As shown, the prefabricated integrated electrical box component of this invention is implemented as follows: The system includes a precast concrete component 1 (reinforced concrete structure), a steel horizontal base 2, a vertical steel section 3 embedded inside the precast concrete component 1, an electrical box 4 embedded inside the precast concrete component 1, a pre-embedded downline conduit 5 embedded inside the precast concrete component 1, a pre-embedded upline conduit 6 embedded inside the precast concrete component 1, and a grounding wire 7 embedded inside the precast concrete component 1 connecting the electrical box 4 and the vertical steel section 3. The electrical box 4 is located between the pre-embedded downline conduit 5 and the pre-embedded upline conduit 6. The inner cavity of the electrical box 4 is connected to the pipe holes of the pre-embedded downline conduit 5 and the pre-embedded upline conduit 6. The steel horizontal base 2 is located below the precast concrete component 1. The lower end of the vertical steel section 3, which protrudes from the lower end of the precast concrete component 1, is fixed to the steel horizontal base 2. The steel horizontal base 2 extends along the thickness direction of the precast concrete component 1, which facilitates welding with the floor slab reinforcement 12 to form a whole and facilitates the vertical installation of the precast concrete component 1.

[0024] Angle steel plates 301 are welded to both sides of the vertical steel section 3, and the vertical steel section 3 and angle steel plates 301 are welded and fixed to the steel horizontal base 2.

[0025] Preferably, the precast concrete component 1 has toothed joint structure 8 on both sides, which can form an I-shaped joint with the surrounding masonry 9 to satisfy the interlocking force between the masonry 9 and the precast integrated electrical box component.

[0026] Preferably, an identification electronic tag is embedded inside the precast concrete component 1.

[0027] Preferably, the steel horizontal base 2 includes two horizontally parallel I-beams 201 and a horizontal brace 202 connecting the two horizontal I-beams 201.

[0028] By using horizontal I-beams 201 and vertical steel sections 3, the structural rigidity is met while standard steel materials are readily available and low in cost. Horizontal I-beams 201 can be replaced by horizontally set channel steel or angle steel.

[0029] The vertical steel section 3 is perpendicular to the horizontal steel base 2. This is to ensure that the precast concrete component 1 of the precast integrated electrical box is in a vertical state after the precast integrated electrical box component is installed, thus ensuring the installation quality.

[0030] Preferably, the upper end of the pre-embedded downline conduit 5 embedded inside the precast concrete component 1 is connected to the electrical box 4, and the lower end is bent at a 90-degree angle to connect with the horizontal conduit 10 pre-embedded in the construction layer, so as to facilitate connection with the horizontal conduit 10 pre-embedded in the construction layer. The pre-embedded downline conduit 5 includes a straight pipe 501 vertically installed in the precast concrete component 1 and a 90-degree bend 502 connected to the lower end of the straight pipe 501. Alternatively, the lower end of the pre-embedded downline conduit 5 can also be directly bent, forming a 90-degree bend at the lower end of the pre-embedded downline conduit 5 that can connect with the horizontal conduit 10 pre-embedded in the construction layer.

[0031] The method of using the prefabricated integrated electrical box component of this invention is implemented as follows, including the following steps: S1: When manufacturing prefabricated integrated electrical box components, based on the building information (such as project name, floor height, building and unit), the prefabricated integrated electrical box components are manufactured and the information is entered at a site outside the construction site. After passing the acceptance test, they are ready for use and transported to the construction site for installation when the construction node arrives. S2: During the building structure construction phase, the prefabricated integrated electrical box components are transported to the construction site that matches the building information in advance. After the floor slab structure template 11 is completed, the layout and positioning are checked and the installation position is verified to be correct. The prefabricated integrated electrical box components are hoisted to the installation position using a tower crane and installed and fixed on the floor slab structure template 11. After the building information is verified to be correct and the acceptance is qualified, the floor slab structure reinforcement 12 construction begins. The floor slab structure reinforcement 12 is welded to the steel horizontal base 2 to form a whole and welded to the grounding system. Then, the horizontal conduit 10 is pre-embedded in the floor slab structure 13. The horizontal conduit 10 is connected to the 90-degree bend 502 of the pre-embedded down conduit 5 of the prefabricated integrated electrical box component. The pre-embedded down conduit 5 and horizontal conduit 10 are pre-embedded and installed at this location. After acceptance, the structural concrete is poured. S3: During the wall construction stage, the masonry 9 around the prefabricated integrated electrical box component is built. The masonry 9 is embedded in the toothed joint structure 8 of the prefabricated integrated electrical box component, so that the prefabricated integrated electrical box component and the surrounding masonry 9 form an interlocking joint.

[0032] Since S2 has been correctly positioned, the wall surface and the prefabricated integrated electrical box components are flat after this stage is completed; During the decoration construction phase, since the pre-embedded upward conduit 6, pre-embedded downward conduit 5 and horizontal conduit 10 have been installed in steps S1 and S2, no secondary piping is required in this phase. The wires can be directly threaded without the need for secondary wire groove opening, and the wall will not be damaged.

[0033] The steel bars 101 of the precast concrete component 1 of the precast integrated electrical box are connected to the steel bars of the upper floor slab. The end of the pre-embedded upward conduit 6 in the precast concrete component 1 that passes through the top of the precast concrete component 1 is connected to the horizontal conduit 10 of the upper floor slab (ceiling) through a bend, or connected to one of the straight pipes 501 of the precast integrated electrical box component on the upper floor, so as to connect to the main power line to guide the power to the upper floor (such as the upper floor of a duplex or the upper floor of a villa).

Claims

1. A prefabricated integrated electrical box component, characterized in that, The system includes precast concrete components, a steel horizontal base, vertical steel sections embedded inside the precast concrete components, an electrical box embedded inside the precast concrete components, a pre-embedded down-line conduit embedded inside the precast concrete components, a pre-embedded up-line conduit embedded inside the precast concrete components, and a grounding wire embedded inside the precast concrete components connecting the electrical box and the vertical steel sections. The electrical box is located between the pre-embedded down-line conduit and the pre-embedded up-line conduit, and the inner cavity of the electrical box is connected to the pipe holes of the pre-embedded down-line conduit and the pre-embedded up-line conduit. The steel horizontal base is located below the precast concrete components, and the lower end of the vertical steel section that extends out of the lower end of the precast concrete components is fixed to the steel horizontal base.

2. The prefabricated integrated electrical box component according to claim 1, characterized in that, The precast concrete component has a toothed joint structure on both sides.

3. The prefabricated integrated electrical box component according to claim 1 or 2, characterized in that, It is equipped with identification electronic tags embedded inside the precast concrete components.

4. The prefabricated integrated electrical box component according to claim 1 or 2, characterized in that, The upper end of the pre-embedded downline conduit embedded inside the precast concrete component is connected to the electrical box, and the lower end is bent at 90 degrees to connect with the horizontal conduit pre-embedded in the construction layer.

5. The method of using the prefabricated integrated electrical box component according to any one of claims 1-4, characterized in that, Includes the following steps: S1: When manufacturing prefabricated integrated electrical box components, the prefabricated integrated electrical box components are manufactured at a site other than the construction site, and the building information is entered. When the construction node arrives, they are transported to the construction site for installation. S2: During the building structure construction phase, prefabricated integrated electrical box components are transported to the construction site that matches the building's information in advance. After the floor slab structure formwork is completed, a tower crane is used to lift the prefabricated integrated electrical box components to the installation position and install and fix them on the floor slab structure formwork. Then, the floor slab structure reinforcement construction begins. The floor slab structure reinforcement is welded to the steel horizontal base to form a whole and welded to the grounding system. Subsequently, horizontal conduits are pre-embedded in the floor slab structure. The horizontal conduits are connected to the lower end of the pre-embedded down conduits at the bottom of the prefabricated integrated electrical box components to complete the pre-embedded down conduits and horizontal conduits at this location. Then, the structural concrete is poured. S3: During the wall construction phase, the masonry around the prefabricated integrated electrical box component is built. The masonry is embedded into the toothed joint of the prefabricated integrated electrical box component, so that the prefabricated integrated electrical box component and the surrounding masonry form an interlocking joint.

6. The method of use according to claim 5, characterized in that, After completing step S2, the reinforcing bars of the precast concrete component of the precast integrated electrical box are connected to the reinforcing bars of the upper floor slab. The end of the pre-embedded upward conduit in the precast concrete component that passes through the top of the precast concrete component is connected to the horizontal conduit of the upper floor slab through a bend, or connected to one of the straight pipes of the precast integrated electrical box component on the upper floor.

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