Embedded flush modular electrical connector backshell

Abstract

The present application relates to the technical field of electrical device, specifically relates to a kind of embedded flush modular electrical connector bottom box.The bottom box includes bottom box body, guiding structure, mounting flange, support structure and cover piece, guiding structure is arranged in module cavity inner wall, for with electrical module cooperation part sliding fit realizes X, Y direction positioning, mounting flange is formed by the extension of bottom box body side wall, and the top surface of cover piece is flush with the finish surface after installation.The present application solves the problem of insufficient space of existing 86 type bottom box, chaotic wiring management and lack of construction reference, improves construction efficiency and installation accuracy, and can be widely used in residential, office and commercial space electrical device installation.

Description

Technical Field

[0001] This invention relates to the field of electrical installation technology, specifically to an embedded flush-mount modular electrical connector back box. This back box is suitable for use with flush-mount socket modules, switch modules, and intelligent electrical modules. It is pre-embedded in walls or various decorative panels, providing installation space, guidance and positioning, construction reference, and panel transition interface for the electrical modules, while also being compatible with traditional 86-type electrical panels. Background Technology

[0002] The applicant had previously filed a patent application for an embedded flush modular electrical connection platform, providing a flush installation solution for electrical panels and mounting bases, as well as a quick-release solution for electrical modules. However, during subsequent prototyping and verification, the applicant discovered the following problems with the base box used in the above solution and the existing 86-type base box: insufficient space in the module cavity, making it difficult to arrange wires within the cavity; large-section rigid wires have large bending radii, making orderly arrangement difficult; in multi-cavity versions, there is a lack of wire transfer space between adjacent module cavities, and no place to place parallel connectors; there is a lack of effective isolation measures during finishing construction, and curing materials easily adhere to the electrical panel; and the flush installation lacks clear construction benchmarks, with on-site positioning relying on manual estimation, making it difficult to guarantee accuracy. Summary of the Invention

[0003] To address the above problems, this invention proposes an embedded flush modular electrical connector back box and its installation method. The technical solution is as follows: This invention provides an embedded flush modular electrical connector back box, with the insertion and removal direction of the electrical module (3) relative to the back box body (1) as the Z direction, and two mutually perpendicular directions in a plane perpendicular to the Z direction as the X and Y directions. The back box includes a back box body (1), a guide structure (12), a mounting flange (11), a support structure (16), and a cover (2). The base box body (1) has at least one module cavity (15), and the side wall is provided with an inlet (111) for external wires to pass through; the guide structure (12) is provided on the inner wall of the module cavity (15), integrally formed with the base box body (1), and is used to slide with the electrical module mating part (31) to realize the positioning of the electrical module (3) in the X and Y directions; the mounting flange (11) extends outward from the side wall of the base box body (1) to form a complete substrate area covering the edge of the mounting base opening; the support structure (16) is provided in the module cavity (15), integrally formed with the base box body (1), and is provided with an electrical module bridging component mounting screw hole (17) for detachable connection with the electrical module bridging component (32); the cover part (2) is integrally formed with the base box body (1) or detachably connected through the cover part connecting structure (14), and after installation, its top edge (27) is flush with the finished surface (42).

[0004] In the multi-cavity version, a through cavity (19) is provided between adjacent module cavities (15), which is connected to each module cavity (15) and is used to accommodate wires and parallel connectors. The wires can turn in the through cavity (19) and enter any adjacent module cavity (15), thus solving the problem of difficult parallel management in the multi-cavity version.

[0005] In some embodiments, the guide structure (12) extends along the Z direction, with one end connected to the bottom plate of the base box body (1) and the other end suspended above the opening of the module cavity (15). A wire receiving and guiding space (112) is formed between the guide structure (12) and the inner wall of the module cavity (15). A sliding fit pair is formed between the guide structure (12) and the electrical module mating part (31). The sliding fit pair includes the mating of a convex rail and a concave rail. The convex rail can be provided on one side of the guide structure (12) or on one side of the electrical module mating part (31), and the concave rail is provided on the corresponding other side. The two cooperate with each other to realize the positioning of the electrical module (3) in the X and Y directions. The suspended end of the guide structure (12) can also be provided with a traditional 86-type electrical panel fixing screw hole (13) to achieve backward compatibility with traditional installation methods.

[0006] In some embodiments, the cover connection structure (14) includes engaging grooves on opposite sides of the top opening edge of the bottom box, arranged symmetrically with a straight line perpendicular to the Z direction as the axis of symmetry. The cover (2) can be rotated 180° around the axis of symmetry and installed in two different orientations, improving installation flexibility.

[0007] In some embodiments, the cover (2) includes a cover body (21) and an isolation frame (22). The isolation frame (22) is located on the top surface of the cover body (21) and protrudes around the opening (26) along the direction of electrical module pull-out. Its top edge (27) is flush with the finished surface (42) and serves as a positioning reference for finishing construction. The isolation frame (22) forms an isolation cavity around the opening (26) to isolate the electrical panel (33) from curing materials such as mortar, putty, or paint during finishing construction to prevent adhesion. After construction is completed, the electrical module (3) can be pushed in or pulled out as a whole at any time.

[0008] In some embodiments, the inner edge of the isolation frame (22) near the opening (26) is recessed outward to form a step (23), and the bearing part (34) on the electrical module (3) is pressed onto the step (23) to achieve bearing and positioning of the electrical module (3) in the Z direction and X and Y directions. The step (23) and the bearing part (34) are axially pressed together, which can achieve stable bearing without interference fit, and reduce the machining accuracy requirements of the mating surface while ensuring smooth insertion and removal.

[0009] In some embodiments, the cover (2) is made of transparent, semi-transparent or opaque colored material. When the material is transparent or semi-transparent, the light (36) emitted by the light-emitting element (35) of the electrical module is conducted through the support part (34) to the step (23), and then through the inner edge of the isolation frame (22) to the top edge (27) to pass through, forming the light-emitting outline around the electrical panel (33); when the material is opaque colored material, it forms a customized match in color or texture with the mounting base.

[0010] In some embodiments, the Z-direction position of the mounting flange (11) on the side wall of the base box body (1) is set according to the preset mounting base thickness. When the mounting flange (11) is attached to the back of the mounting base, the top edge (27) of the cover (2) is naturally flush with the finished surface (42) without additional adjustment. A series of specifications are provided for mounting bases of different thicknesses. The module cavity (15), guide structure (12) and support structure (16) of each specification base box are the same, and the same electrical module (3) can be interchanged in the series.

[0011] The present invention also provides a method for in-situ surface finish installation of an embedded flush modular electrical connector back box, comprising the following steps: determining the position of the finished surface of the finish on the mounting base (4) and popping out the layout reference line; opening mounting holes on the mounting base (4); applying mortar or adhesive material to the back of the mounting flange (11) and around the back box and then pushing the back box into the mounting holes; pressing and adjusting the back box so that the top edge (27) of the cover assembly (2) is aligned with the layout reference line; completing the surface leveling layer (41) construction so that the finished surface (42) is flush with the top edge (27); introducing and connecting wires; and pushing in the electrical module (3) to complete the installation.

[0012] The present invention also provides a method for installing an embedded flush modular electrical connector back box, comprising the following steps: opening mounting holes on the mounting base surface (44) of the plate; inserting the back box through the mounting holes from the back side (45) of the mounting base surface so that the cover (2) protrudes from the front side; placing the plate with the front side facing the reference plane (43) so that the top edge (27) of the cover (2) is aligned with the reference plane (43); injecting adhesive material between the mounting flange (11) and the back side (45) of the mounting base surface to fix it; installing the plate together with the back box to the installation position; introducing wires and connecting them; pushing in the electrical module (3) to complete the installation.

[0013] The beneficial effects of the present invention are as follows: the top edge (27) of the cover (2) is used as the positioning reference for the finishing construction, which solves the problem of missing installation reference; the through cavity (19) solves the problem of difficult parallel management of multiple cavity versions; the isolation frame (22) isolates the cavity, which solves the problem of interference of finishing construction on electrical panel (33); the Z-direction position design of the serialized flange (11) achieves full coverage of installation base surfaces of different thicknesses; the guide structure (12) is compatible with screw holes (13) to achieve downward compatibility with traditional 86-type electrical panels; the axial pressing fit between the step (23) and the bearing part (34) achieves multi-directional bearing positioning of electrical module (3), which reduces the processing accuracy requirements while ensuring smooth insertion and removal. Attached Figure Description

[0015] Figure 1 Top view of a single-cavity bottom box; Figure 2 This is a cross-sectional view of a single-cavity bottom box; Figure 3 Top view of the multi-cavity bottom box; Figure 4 This is a cross-sectional view of a multi-cavity bottom box; Figure 5 This is a top view of the cover assembly; Figure 6 This is a bottom view of the cover assembly; Figure 7 This is a cross-sectional view of the cover assembly; Figure 8 Assembly diagram of the bottom box, cover assembly, electrical module, and electrical module bridging component; Figure 9 This is an assembly diagram of the electrical module bridging components; Figure 10 This is a schematic diagram of the in-situ finishing process for a square panel; Figure 11 A schematic diagram of in-situ finishing construction for irregularly shaped panels; Figure 12 This is a schematic diagram of the board installation process.

[0016] Explanation of reference numerals in the attached figures 1-Base box body, 11-Mounting flange, 12-Guide structure, 13-Traditional 86-type electrical panel fixing screw hole, 14-Cover connection structure, 15-Module cavity, 16-Support structure, 17-Electrical module bridging component mounting screw hole, 18-Positioning part, 19-Through cavity, 111-Cable inlet, 112-Wire receiving and guiding space.

[0017] 2-Cover assembly, 21-Cover plate body, 22-Isolation frame, 23-Step, 24-Connecting buckle, 25-Base box positioning protrusion frame, 26-Opening, 27-Top edge.

[0018] 3-Electrical module, 31-Electrical module mating part, 32-Electrical module bridging part, 33-Electrical panel, 34-Supporting part, 35-Electrical module light-emitting element, 36-Light beam.

[0019] 4-Installation base surface, 41-Surface leveling layer, 42-Finished surface, 43-Reference plane, 44-Plate installation base surface, 45-Back side of the plate installation base surface. Detailed Implementation

[0021] 1. Examples of applicable scenarios for single-cavity bottom boxes The single-cavity base box has a modular cavity (15) that is suitable for mounting a single electrical module (3).

[0022] In this embodiment, the single-cavity base box is mainly used at the end of a circuit. These points only need to install a single electrical module with independent function, without needing to be connected to other modules via a circuit.

[0023] However, the existing 86-type junction box module cavity space is insufficient, and it is difficult to control the bending radius of the wires during construction, especially for hard wires with a cross-sectional area of ​​4mm² and above, which have a large bending radius and are difficult to arrange in an orderly manner in the narrow 86-type junction box. Electricians often forcibly press the socket or switch into the junction box and tighten the screws, completing the installation by pressing the wires, which may cause the wiring terminals to be pulled out, resulting in poor contact, wire bending fatigue fracture and other safety hazards. The present invention preferably uses a 95mm×95mm junction box, with the guide structure (12) extending along the Z direction and integrally formed with the bottom plate of the junction box body (1), and the other end suspended in the air facing the opening of the module cavity (15). A sliding fit pair is formed between the guide structure (12) and the electrical module mating part (31). In a preferred embodiment, the guide structure (12) is a convex rail, and the electrical module mating part (31) is a matching concave rail. When the electrical module (3) is pushed in, the concave rail of the electrical module mating part (31) fits into the convex rail of the guide structure (12) and slides in the Z direction until it is in place. In other embodiments, the positions of the convex rail and the concave rail can be interchanged, that is, the guide structure (12) is a concave rail, and the electrical module mating part (31) is a convex rail. Both can achieve precise positioning in the X and Y directions. A wire receiving and guiding space (112) is specially designed between the guide structure (12) and the inner wall of the module cavity (15) to provide an orderly arrangement channel for the wires and effectively accommodate large cross-section hard wires, thus fundamentally solving the above problems.

[0024] Typical application scenarios include: balcony lighting switches, balcony single sockets, bathroom independent sockets, hallway single-pole switches, storage room lighting switches, etc. The common characteristics of these locations are: the circuit wires are directly introduced, wired locally, and used locally, without serving as a branch for other locations.

[0025] 2. Practical Application Examples of Multi-Cavity Base Boxes The multi-cavity base box has at least two adjacent module cavities (15) and is suitable for the simultaneous installation of multiple electrical modules (3).

[0026] In this embodiment, the multi-cavity junction box is mainly used at circuit transfer points. These points not only need to install multiple electrical modules, but also serve as transfer points to other points via parallel lines, resulting in a large number of parallel connection connectors being gathered inside the junction box.

[0027] In existing technology, multi-socket switches are typically implemented by horizontally splicing multiple 86-type junction boxes. These boxes are connected in series via a narrow 20mm inlet cable, forcing wires and parallel connectors into the already cramped space. In actual installation, electricians face the following scenario: several incoming and outgoing wires, along with parallel connectors, are crammed into a single 86-type junction box. The wires become tangled, and there's nowhere to place the parallel connectors; they are simply forced into the box and then the socket is closed to compress them. Multiple wires pass through the 20mm conduit between the junction boxes simultaneously, creating extremely limited space. The wire insulation is at risk of damage due to prolonged pressure and friction. During later maintenance, electricians often find themselves facing a tangled mess of wires when opening the box, and a slight mishap could lead to contact with live parts, resulting in extremely low repair efficiency and safety hazards.

[0028] The multi-cavity box of the present invention has a through cavity (19) between adjacent module cavities (15). The through cavity (19) is connected to the bottom of each module cavity (15), and the cross-sectional area is sufficient to accommodate multiple wires and parallel connectors. The wires can be turned in an orderly manner within the through cavity (19) and enter any adjacent module cavity (15). The parallel connectors are centrally located within the through cavity (19), and the internal space of each module cavity (15) is fully released, fundamentally solving the problem of chaotic parallel management in existing multi-cavity boxes.

[0029] Typical application scenarios include: living room TV background wall, sofa background wall, kitchen countertop, bedside area, and dining room. The common characteristics of the above locations are: concentrated power demand, multiple functional modules such as sockets, switches, and network interfaces arranged side by side, and the function of connecting to adjacent rooms or other locations via parallel wiring. The junction boxes contain a large number of wires and parallel connectors with large cross-sectional areas.

[0030] 3. Installation flange Z-direction positioning example The Z-direction position of the mounting flange (11) on the side wall of the base box body (1) of the present invention is preset according to the thickness of the corresponding mounting base surface (4). When the mounting flange (11) is attached to the back of the mounting base surface (4), the top edge (27) of the cover (2) and the finished surface (42) of the front surface of the mounting base surface are on the same plane, and flush installation can be achieved without additional adjustment.

[0031] For mounting base surfaces (4) of different thicknesses, corresponding back box specifications for different Z-direction flange positions are provided, including but not limited to specifications that adapt to the thickness of various finishing materials such as ceramic tiles, stone, wall panels, and wood veneer panels. The same electrical module (3) can be interchanged and installed between back boxes of different specifications, realizing the comprehensive coverage of different mounting base surfaces (4) by the modular system (see Figure 12 ).

[0032] Taking the installation of wall tiles and custom furniture boards as examples: The default distance from the installation flange (11) to the top edge (27) of the cover (2) is 10mm, which is slightly larger than the thickness of mainstream glazed tiles and polished glazed tiles (the thickness of the wall tiles is usually 7-9mm). This allows for the thickness of the tile adhesive layer and the redundancy of the leveling process, ensuring that the top edge (27) of the cover (2) is flush with the finished surface (42) of the tile after the tiles are laid. It is also compatible with the thickness of the conventional finished surface after the paint finish putty construction and leveling. When the mounting base (4) is a custom-made thick board, the standard double-sided particleboard finishing thickness is usually 18mm. If the default 10mm flange specification is still used, the following two situations will occur: First, the top edge (27) of the cover (2) is lower than the finished surface (42) of the front of the board, the panel is recessed, and the flush effect is destroyed; Second, if the flush effect is forcibly achieved, a flange groove needs to be opened on the back of the board to insert the mounting flange (11) into the board, which will result in local thinning of the board, a significant reduction in the effective bonding area between the mounting flange (11) and the board, a serious decrease in the strength of the bottom box installation area, and a risk of falling off.

[0033] When the mounting base (4) is a medium-thickness plate such as stone, its finished surface thickness is usually 10-12mm. If the above-mentioned 18mm flange specification is used, the top edge (27) of the cover (2) is higher than the finished surface (42) of the front of the plate, and the panel protrudes, which also destroys the flush effect.

[0034] Therefore, it is evident that a single set of mounting flanges (11) with a fixed Z-direction position cannot simultaneously accommodate both thick and thin sheet metal. This invention addresses this by pre-setting the Z-direction position of the mounting flange (11) to precisely match the thickness of the corresponding mounting base (4). During installation, the base box is inserted into the mounting hole from the back of the mounting base (4), and the mounting flange (11) naturally fits against the back of the mounting base (4). The top edge (27) of the cover piece (2) and the finished surface (42) of the front of the mounting base are on the same plane, thus completely solving the aforementioned problem (see [link]). Figure 12 ).

[0035] 4. Cover Fitting Transition Embodiment In traditional building electrical installation systems, junction boxes are typically 83mm x 83mm, and control panels are 86mm x 86mm. This size is not accidental—an 86mm panel can perfectly cover the opening edge of an 83mm junction box, achieving concealment and a neat finish. This size relationship has been used to this day, forming the industry-standard "86-type" system. However, this size logic also brings unavoidable problems. The inner cavity of the junction box is constrained by the 83mm outer frame, resulting in extremely limited effective space. This is the root cause of the construction pain points and safety hazards described in Examples 1 and 2, such as difficulties in wire storage, lack of space for parallel connectors, and difficulty in orderly arrangement of large-section rigid wires.

[0036] To fundamentally solve the above problems, the base box body (1) of the present invention is preferably 95mm×95mm in size. Compared with the traditional 83mm base box, the size is only increased by about 12mm, but the internal cavity space released is sufficient to set up a dedicated wire-accommodating guide space (112) between the guide structure (12) and the inner wall of the module cavity (15). The multi-cavity base box can also set up a through cavity (19) between adjacent module cavities (15), which thoroughly improves the wire storage conditions and eliminates construction safety hazards. After the base box body (1) is enlarged to 95mm, the traditional 86mm panel can no longer effectively cover it, and there is a gap in the size connection. At the same time, modern home decoration generally pursues a minimalist style. The electrical panel (33) adapted to the present invention is preferably 79mm×79mm in size - compared with the traditional 86mm panel, the frame is narrower and the visual lightness is lighter. It has independent aesthetic value in itself. It is an active choice that takes into account both function and aesthetics, rather than a compromise result of passive adaptation.

[0037] This results in a size difference between the large base box and the small panel, which cannot be directly connected. The cover assembly (2) is designed to solve this transition problem. The cover assembly (2) is detachably connected to the top opening edge of the base box body (1) through the cover assembly connection structure (14). The outer contour of its cover plate body (21) completely covers and closes the 95mm opening of the base box body (1). The central opening (26) matches the 79mm electrical panel (33), providing a passage for the electrical module (3). The isolation frame (22) is set on the top surface of the cover plate body (21) and protrudes along the Z direction around the opening (26). Its top edge (27) is flush with the finished surface of the mounting base. After the electrical module is pushed in, the top surface of the electrical panel is flush with the top edge (27), achieving an overall flush effect. The bottom box positioning protrusion frame (25) is located on the side of the cover plate body (21) facing the bottom box opening, and cooperates with the inner wall of the cavity of the bottom box body (1) to achieve positioning in the X and Y directions; the connecting buckle (24) engages with the cover fitting connection structure (14), and the cover fitting (2) and the bottom box body (1) are designed separately. The bottom box body (1) uses ordinary materials to reduce costs, and the cover fitting (2) can be made of transparent, semi-transparent or colored materials according to requirements. After installation, the two form a reliable fixed connection. The above structure allows the construction advantages of the large bottom box and the aesthetic advantages of the small panel to be realized at the same time, and the two no longer restrict each other.

[0038] Furthermore, the adaptability of the cover assembly (2) extends not only to the size level but also to the shape level. The opening of the base box body (1) is a standard square, while the shape of the isolation frame (22) and opening (26) of the cover assembly (2) can match the shape of the corresponding electrical panel (33) and electrical module (3), including square, round, or other irregular shapes. By replacing the cover assembly (2) with different shapes, the same 95mm square base box body (1) can be matched with various panel forms such as round panels and irregularly shaped panels, without the need to develop a separate base box for different panels, giving the entire installation system greater flexibility and expandability (see Figure 11 ).

[0039] The step (23) is located on the inner edge of the isolation frame (22) near the opening (26), forming a ring structure that recedes outward from the inner edge. When the electrical module (3) is pushed in, the corresponding bearing part (34) on the electrical module (3) presses against the step (23), realizing the bearing and positioning of the electrical module (3) in the Z direction; the receding distance of the step (23) is adapted to the width of the bearing part (34), and at the same time, it realizes the limiting in the X and Y directions. The above positioning is achieved by the axial pressing fit between the bearing part (34) and the step (23), without the need for an interference fit between the outer wall of the bearing part (34) and the inner wall of the opening (26), which ensures smooth insertion and removal of the electrical module (3) while reducing the machining accuracy requirements of the relevant mating surfaces. (See Figure 8 ) When both the cover (2) and the support (34) are made of transparent or semi-transparent material, the light (36) emitted by the light-emitting element (35) of the electrical module is conducted through the support (34) to the step (23), and then upward along the inner edge of the isolation frame (22) to the top edge (27) to be emitted, forming a continuous light-emitting outline around the electrical panel (33) (see Figure 8 (Enlarged details). The light guide path is achieved by relying on the structure of the step (23) and the isolation frame (22) itself, without the need for additional light guide devices. When the cover (2) is made of an opaque colored material, it can be matched with the mounting base in terms of color or texture to meet the decoration needs of different styles.

[0040] The cover assembly (2) adopts a separate design from the bottom box body (1), which has the following advantages: 1. Reduce costs: The bottom box body (1) is made of ordinary plastic material, and the lid assembly (2) is made of transparent, semi-transparent or colored material. Separate injection molding reduces the overall manufacturing cost.

[0041] 2. Flexible materials: The cover (2) can be made of different materials according to the needs. When it is transparent or semi-transparent, it can achieve the light guide contour effect. When it is opaque and colored, it can achieve the color customization matching with the mounting base.

[0042] 3. Shape adaptation: By replacing the cover parts (2) with different shapes, the same base box body (1) can be adapted to square, round or irregular electrical panels (33) without the need to redevelop the base box.

[0043] 4. Size transition: The cover assembly (2) establishes a structural transition between the 95mm base box body (1) and the 79mm electrical panel (33), so that the construction advantages of the large base box and the aesthetic advantages of the small panel can be realized at the same time.

[0044] 5. Embodiment of the Adaptation of Electrical Module Bridging Components and Back Box The base box of this invention is mainly used in conjunction with a quick-connect modular electrical module. One of the core components of this electrical module is the electrical module bridge (32), which provides electrical interfaces with different functions such as sockets, switches, and network interfaces for the electrical module (3), and also serves as a structural link for detachable connection between the electrical module and the base box.

[0045] To accommodate the aforementioned bridging component (32), a support structure (16) is provided inside the module cavity (15) of the base box body (1). The support structure (16) is integrally formed with the base box body (1) and has a positioning part (18) for positioning the electrical module bridging component (32) in the X and Y directions. After the electrical module bridging component (32) is installed, a wire accommodating space is formed between it and the bottom surface of the base box. Electrical module bridging components (32) with different functions can be directly replaced without disassembling the base box body (1), so that the same base box body (1) can be adapted to electrical modules with different functions. Conversely, when the interface structure and positioning dimensions of the electrical module bridging component (32) are the same, the corresponding electrical modules can be interchanged and installed between base boxes of different specifications, realizing bidirectional flexible adaptation between the electrical module and the base box body (1) (see Figure 9 ).

[0046] During installation, first, the wire is introduced into the module cavity (15) through the inlet (111) and connected to the electrical module bridge (32). It is then fixed with screws to the mounting screw holes (17) of the electrical module bridge. Next, the electrical module (3) is pushed into the module cavity (15) as a whole, so that the electrical module bridge (32) cooperates with the positioning part (18) of the support structure (16) to complete the installation of the electrical module (3). This installation method is consistent with the steps of the installation method described in claims 19 and 20.

[0047] 6. Example of an anti-sticking and light-guiding enclosure The isolation frame (22) is located on the top surface of the cover plate body (21), protruding along the Z direction around the perimeter of the opening (26), and its top edge (27) is flush with the finished surface (42). The design of the isolation frame (22) simultaneously achieves three functions: anti-stick isolation, light guiding contour, and visual transition.

[0048] An isolation frame (22) forms an isolation cavity around the opening (26). During the installation of the base surface finish, the electrical module (3) has not yet been pushed in, and the isolation cavity is in an open state. During the construction process, the curing materials such as mortar, putty, or paint are blocked by the isolation frame (22) and cannot come into contact with and adhere to the inner wall of the module cavity (15) and the surface of the bridging component (32). If necessary, a temporary protective cover can be installed. The temporary protective cover is detachably connected to the opening (26) of the isolation frame (22) to further isolate the module cavity (15) from the external environment. After the construction is completed, it is removed and discarded.

[0049] After construction is completed, the electrical module (3) and the electrical panel (33) are pushed into the bottom box as a whole. The electrical panel (33) is housed in the isolation cavity. The electrical module (3) can be pulled out as a whole at any time. Later maintenance and replacement are not affected by the finishing material.

[0050] Light guiding contour function: When the cover (2) is made of transparent or semi-transparent material, the isolation frame (22) functions as a light guiding channel. The light (36) emitted by the electrical module light-emitting element (35) is conducted through the support part (34) to the step (23), and then upward along the inner edge of the isolation frame (22) to the top edge (27) to shine through, forming a continuous light-emitting contour around the electrical panel (33), which has both functional indication and decorative effects. When the cover (2) is made of opaque colored material, it can be customized with the mounting base in terms of color or texture (see Figure 8 Zoom in on the details.

[0051] Visual transition function: The top edge (27) of the isolation frame (22) is flush with the finished surface (42), forming a closed interface between the mounting base and the electrical panel (33), naturally connecting the materials and colors of the two, eliminating the abruptness caused by the direct splicing of the mounting base and the electrical panel (33). When the isolation frame (22) and the opening (26) are round or other irregular shapes, the shape transition between the round panel, the irregular panel and the square mounting base opening can also be realized, so that electrical panels (33) of different shapes can form a neat and continuous visual connection with the finished surface (42) (see Figure 11 ).

[0052] 7. Assembly Example of Irregularly Shaped Panel This embodiment uses a circular panel as an example to illustrate the assembly relationship between the irregularly shaped panel and the base box.

[0053] The base box body (1) adopts the standard 95mm×95mm specification. The module cavity (15), guide structure (12), support structure (16) and cover connection structure (14) are all consistent with the standard square panel installation scheme. For the assembly requirements of the round panel, only the cover (2) needs to be replaced with a round cover. The cover plate body (21), base box positioning protrusion frame (25) and connecting buckle (24) of the round cover are the same as the standard cover and can be directly connected to the base box body (1) without any modification to the base box body (1).

[0054] The circular cover fitting has a circular frame and openings, preferably 70mm in diameter, to achieve a neat finish between the circular electrical panel (33) and the mounting base. After the electrical module (3) is pushed in, the circular electrical panel (33) is accommodated in the isolation cavity formed by the circular isolation frame (22). The top surface of the electrical panel (33) is flush with the top edge (27) of the isolation frame (22) and the finished surface (42), achieving a flush installation effect for the circular panel (see [reference]). Figure 11 ).

[0055] The above-mentioned circular panel assembly scheme is also applicable to other irregularly shaped panels. By replacing the corresponding cover fitting (2), the same specification base box body (1) can be adapted to square, circular or other irregularly shaped electrical panels (33). The base box body (1) does not need to be redeveloped, realizing the full compatibility of the installation system with various panel shapes. In addition to the circular shape, the isolation frame (22) and opening (26) can also be customized into other irregular shapes such as heart shape and rhombus shape according to the usage scenario to meet the needs of personalized decoration scenarios such as wedding rooms. The base box body (1) does not need to be modified.

[0056] 8. In-situ finish installation examples This embodiment describes a method for fixing the base box to a painted wall with mortar. The mounting base (4) is concrete or masonry, and the finished surface (42) is a painted finish. This embodiment uses mortar fixing as an example. In actual construction, the fixing method of the base box can be selected according to factors such as the material of the mounting base and the construction conditions, including but not limited to mortar fixing, expansion screw fixing, structural adhesive or other bonding materials fixing, etc. This invention does not limit this method.

[0057] Construction preparation Before construction, the painter, based on the thickness of the finished paint finish (usually 8-12mm, including putty and paint layers), marks the position of the finished surface (42) on the adjacent wall, floor, or ceiling surfaces that intersect with the installation base surface (4), using a chalk line or a marker (commonly known as "dotting" on construction sites). The electrician then places the bottom of the laser sight against the top edge (27) of the cover assembly (2), with the laser line and the top edge (27) on the same plane. When the laser line coincides with the chalk line or dot mark, it is confirmed that the depth of the bottom box in the Z direction is in place.

[0058] According to the construction handover, the location of the points is determined, and the wire groove and installation hole are chiseled on the installation base surface (4). Take out the bottom box, and select the corresponding inlet (111) according to the direction of the wire conduit. The inlet (111) on the side wall of the bottom box body (1) adopts a knock-out hole structure. The thin-walled connecting rib is retained during injection molding. During construction, the hole can be knocked off by a tool. The unused inlet (111) is kept closed to prevent mortar from entering the module cavity (15). After knocking out the hole, the wire conduit locking connector is installed at the inlet (111). According to the usage requirements, the cover (2) is installed on the bottom box body (1) by connecting buckle (24) and the cover connection structure (14).

[0059] Base box fixing First, thoroughly wet the inner wall of the mounting hole to fully moisten the substrate and prevent the mortar from losing water too quickly, which would affect the bonding strength. Apply mortar to the back of the mounting flange (11), the four sides and bottom of the base box body (1), and push the base box into the mounting hole so that the cover part (2) is located on the front side of the mounting base surface (4), and press the mounting flange (11) against the wall around the mounting hole. Press and adjust the base box, and use a laser sight to align with the top edge (27) of the cover part (2) and align it with the installation reference line pre-marked by the painter to complete the positioning of the depth in the Z direction and the horizontality in the XY direction. After positioning, scrape off the residual mortar around the base box and wait for the mortar to solidify.

[0060] Subsequent construction After the mortar has hardened, insert the PVC conduit into the conduit locking joint to complete the conduit installation. The wires are then passed through the PVC conduit and introduced into the module cavity (15) through the inlet (111). The wire trough is filled with mortar to level the working surface for the painter. After the painter finishes the putty and paint, the finished surface (42) is flush with the top edge (27) of the cover (2). Connect the wires to the electrical module bridge (32) and install and fix the bridge (32) to the support structure (16). Finally, push the electrical module (3) into the module cavity (15). The electrical panel (33) is flush with the top edge (27) of the cover (2) and the finished surface (42) to complete the installation (see [reference]). Figure 10 ).

[0061] 9. Examples of Tile and Stone Installation This embodiment describes the installation method of the base box on a ceramic tile or stone veneer mounting base. The mounting base (4) is concrete or masonry, and the finished surface is a ceramic tile or stone veneer layer. This embodiment uses mortar fixing and ceramic tile adhesive bonding as examples. In actual construction, the fixing method of the base box and the veneer material can be selected according to factors such as the material of the mounting base and the construction conditions, including but not limited to mortar fixing, ceramic tile adhesive, marble adhesive, AB glue or other bonding materials. This invention does not limit this method.

[0062] Preliminary preparations According to the construction handover, the location of the point is determined, and the corresponding tile or stone is sent to the waterjet processing plant for pre-drilling. The shape of the opening matches the shape of the cover (2) and the isolation frame (22), so that the isolation frame (22) can be inserted into the opening from the back of the tile or stone and out from the front.

[0063] Water and electricity pre-embedded Grooves and mounting holes are drilled in the mounting base, and PVC conduits are pre-embedded. Appropriate lengths of corrugated conduit or flexible conduit such as snakeskin tubing are then connected to these flexible conduits for future use. The reason for replacing the PVC conduit with flexible conduits is that the PVC conduit's position is fixed after pre-embedding. When laying tiles or stone, the junction box needs fine-tuning for alignment. Rigid PVC conduits cannot move with the junction box. Connecting flexible conduits provides sufficient displacement allowance for junction box positioning while ensuring the wires are protected throughout, preventing exposure.

[0064] Installation and construction Remove the bottom box and select the corresponding inlet (111) according to the pipe routing. Use a tool to knock out the opening of the knock-out hole, and keep the unused inlet (111) closed. Install the pipe locking connector at the inlet (111) and insert the end of the flexible wire protection tube into the pipe locking connector. Install the cover (2) onto the bottom box body (1) by connecting buckle (24) and the cover connection structure (14). Place the tile or stone at the corresponding point face down on the reference plane (43), and insert one end of the bottom box cover (2) into the pre-drilled hole from the back of the tile or stone, so that the isolation frame (22) protrudes from the front, and the top edge (27) of the cover (2) is aligned with the reference plane (43). At this time, the mounting flange (11) is located on the back side of the tile or stone, and a gap for adhesive bonding is formed between the mounting flange (11) and the back of the tile or stone. Structural adhesive is injected into the gap between the mounting flange (11) and the back of the tile or stone. After the structural adhesive has solidified, the bottom box and the tile or stone form an integral pre-assembled component. The wire is passed through the flexible conduit and introduced into the module cavity (15) through the inlet (111). The pre-assembled component is fixed to the mounting base (4) according to the tile laying or stone dry hanging process. After the tile adhesive or stone adhesive has solidified, the finished surface (42) is flush with the top edge (27) of the cover assembly (2).

[0065] Subsequent construction Connect the wires to the electrical module bridge (32) and install and fix the bridge (32) to the support structure (16). Finally, push the electrical module (3) into the module cavity (15), and make the electrical panel (33), the top edge (27) of the cover (2), and the finished surface (42) flush with each other to complete the installation.

[0066] 10. Custom Furniture Installation Examples This embodiment describes the installation method of the base box on the cabinet board of a custom furniture unit. Typical application scenarios include locations in custom furniture cabinets such as sideboards, wardrobes, and bookcases where electrical modules need to be installed. The mounting base surface (44) is a commonly used custom furniture board such as double-sided particleboard, and the finished surface is the front of the mounting base surface (44). This embodiment uses self-tapping screws combined with structural adhesive bonding as an example. In actual construction, the fixing method of the base box can be selected according to factors such as the material of the board and the construction conditions. This invention does not impose any restrictions on this.

[0067] Preliminary preparations According to the construction instructions, the location of the point is determined. A trimming machine (commonly known as a milling machine) is used to make a hole in the mounting base (44) of the board. The shape of the hole matches the shape of the cover (2) isolation frame (22). The hole diameter matches the outer diameter of the isolation frame (22), so that the isolation frame (22) can be inserted into the hole from the back (45) of the mounting base and out from the front.

[0068] Water and electricity pre-embedded PVC conduit is laid along the space between the cabinet base and the wall. The ends of the conduit are then connected to flexible conduits of appropriate length, such as corrugated or snakeskin tubing, for wire protection. The wires are pre-threaded into the flexible conduit for later use. The reason for using flexible conduits is that once the PVC conduit is fixed in position, the junction box needs fine-tuning during installation. Rigid PVC conduit cannot move with the junction box. Using flexible conduits provides sufficient displacement for junction box positioning while ensuring the wires are protected throughout, preventing them from being exposed.

[0069] Pre-assembly positioning of base box and sheet metal Remove the bottom box and select the corresponding inlet (111) according to the pipe routing. Use a tool to knock out the opening by tapping the knockout hole. Keep unused inlets (111) closed. Install the pipe locking connector at the inlet (111) and insert the end of the flexible cable protection tube into the pipe locking connector. Install the cover (2) onto the bottom box body (1) by connecting buckle (24) and the cover connection structure (14). Place the plate mounting base (44) face down on the reference plane (43). Insert one end of the bottom box cover (2) into the pre-drilled hole from the back (45) of the plate mounting base, so that the isolation frame (22) protrudes from the front. The top edge (27) of the cover (2) is aligned with the reference plane (43). At this time, the mounting flange (11) is located on the back side (45) of the plate mounting base. The mounting flange (11) is fixed to the back side (45) of the plate mounting base with self-tapping screws. Then, structural adhesive is injected between the mounting flange (11) and the back side (45) of the plate mounting base. The double fixation ensures that the bottom box and the plate form a reliable overall pre-assembled component.

[0070] On-site installation After the structural adhesive has solidified, insert the wires through the flexible conduit into the conduit locking connector and pull them into the inlet (111) and introduce them into the module cavity (15). Fix the cabinet panels to the installation position according to the custom furniture installation process.

[0071] Subsequent construction Connect the wires to the electrical module bridging component (32), and install and fix the bridging component (32) to the support structure (16). Finally, push the electrical module (3) into the module cavity (15), making the electrical panel (33) flush with the top edge (27) of the cover (2) and the front of the plate mounting base (44), thus completing the installation (see [reference]). Figure 12 ).

[0072] 11. Example of gypsum board wall panel installation This embodiment describes the installation method of the base box on a light steel keel partition wall. The installation base consists of a light steel keel frame, a 9mm plywood base layer, and a panel layer. The panel layer includes, but is not limited to, commonly used boards such as paper-faced gypsum board, calcium silicate board, and cement fiberboard. The finished surface is a putty and paint finish layer. In this embodiment, a variant of the installation flange (11) corresponding to the Z-direction position is used for the above-mentioned installation base, so that the top edge (27) of the cover (2) protrudes from the front of the panel layer by approximately the thickness of the putty layer. After the putty is applied by the painter, the finished surface is flush with the top edge (27).

[0073] Water and electricity pre-embedded The PVC conduit is tied and fixed to the light steel keel frame. The end of the conduit is replaced with a flexible conduit such as a corrugated pipe or snake skin pipe of appropriate length. The wire is pre-threaded to the end of the flexible conduit for later use.

[0074] Drywall opening and base box installation After the 9mm plywood base layer and panel layer are completed, the location of the points is determined according to the construction instructions. A trimming machine (commonly known as a milling machine) is used to make holes in the gypsum board and 9mm plywood. The bottom box is removed, and the corresponding inlet (111) is selected according to the pipe routing. The knock-out hole is knocked off with a tool, and the unused inlet (111) is kept closed. A conduit locking connector is installed at the inlet (111), and the cover (2) is installed on the bottom box body (1) by connecting buckle (24) and the cover connection structure (14). The wire is passed from the flexible wire protection tube into the conduit locking connector and introduced into the module cavity (15). The bottom box is pushed into the mounting hole from the front of the gypsum board, and the mounting flange (11) covers the edge of the opening on the front of the gypsum board. Self-tapping screws are used to pass through the gypsum board and lock into the back 9mm plywood base layer to fix the bottom box to the mounting base.

[0075] Subsequent construction After the painter completes the putty and paint application, the finished surface (42) is flush with the top edge (27) of the cover (2). Connect the wires to the electrical module bridge (32) and install and fix the bridge (32) to the support structure (16). Finally, push the electrical module (3) into the module cavity (15), and make the electrical panel (33) flush with the top edge (27) of the cover (2) and the finished surface (42), thus completing the installation.

[0076] 12 Traditional 86-panel backward compatible implementation examples The bottom box of the present invention has a conventional 86-type electrical panel fixing screw hole (13) at the suspended end of the guide structure (12). The screw hole (13) does not affect the sliding mating surface of the guide structure (12), so that the bottom box of the present invention is compatible with the installation method of the conventional 86-type electrical panel while installing the electrical module (3) adapted to the bottom box of the present invention.

[0077] When users need to install a traditional 86-type electrical panel, there is no need to replace the base box body (1). After completing the wiring of the electrical components of the traditional 86-type electrical panel, simply align the panel mounting ears with the screw holes (13), tighten the mounting screws, and snap the panel together to complete the installation. The base box of this invention thus achieves backward compatibility with the installation method of the traditional 86-type electrical panel, while retaining the modular quick-connect advantages of this invention, providing users with a flexible option to use traditional panels during the transition period.

[0078] 13 Examples of Smart Expansion for Ceiling Embedded Structures This embodiment describes an installation method where the base box is pre-embedded in the gypsum board ceiling. Typical application scenarios include ceiling-embedded installation of smart devices such as wireless AP panels and camera panels. The installation base consists of a light steel keel frame, a 9mm plywood base layer, and a gypsum board surface layer. The electrical module (3) is pushed upwards into the base box from the front of the ceiling, and the electrical panel (33) is flush with the finished ceiling surface (42), achieving an integrated embedding effect between the smart device panel and the ceiling.

[0079] The shape of the smart device panel, such as the wireless AP and camera, can be configured as round, square or other shapes according to the device type. The corresponding cover parts (2) are used. The shape of the isolation frame (22) and the opening (26) are matched with the shape of the device panel to achieve a neat finish between the smart device panel and the ceiling mounting base. For the round panel assembly scheme, see Example 7 (Irregular panel assembly example); for the bottom box installation construction process, see Example 11 (wall panel gypsum board installation example).

[0080] The installation method and construction process of the bottom box are the same as those of the gypsum board installation method described in Example 11, and will not be repeated here. The difference is that in this example, the electrical module (3) is a wireless AP or camera and other smart devices. In addition to the power cord, some devices also need to be connected to network cables or signal cables. During construction, the corresponding cables are reserved according to the type of equipment. The wires, network cables or signal cables are introduced into the module cavity (15) from the inlet (111). After connecting the electrical module bridge (32), the electrical module (3) is pushed upward into the module cavity (15). The electrical panel (33) is flush with the finished surface of the ceiling (42) to complete the installation.

[0081] Terminology Explanation: Unless otherwise defined, the technical or scientific terms used in this specification and claims shall have the ordinary meaning understood by one of ordinary skill in the art. Some of the names of construction tools and methods appearing in this specification are customary terms formed by construction personnel in the art through long-term practice, and their meanings are as follows: "Rolling machine" refers to a trimming machine or a router, which is a power tool used for cutting, grooving, and trimming sheet metal. In this invention, "marking" refers to the operation of construction workers using a marker pen or other marking tools to mark the reference position of the finished surface on the wall. In building plastering construction, "marking" also refers to the process of making plaster spots at certain intervals on the wall to control the thickness of the plaster. The two are the same term used in different construction scenarios. "Snake-skin tubing" refers to corrugated tubing or flexible metal tubing, which is a type of flexible conduit used to protect electrical wires. "Corrugated pipe" refers to a flexible pipe with a corrugated structure, used for wire protection. In some regions, construction workers also call the "conduit locking joint" a "screw joint" or a "cup comb".

[0082] The above-mentioned terms are all customary terms familiar to those skilled in the art. After reading the specification and drawings of this invention, those skilled in the art can clearly understand their meanings, and the technical solution will not be unclear.

[0083] Definition of directional terms: In this invention, the insertion and removal direction of the electrical module (3) relative to the base box body (1) is defined as the Z direction, and the two mutually perpendicular directions in the plane perpendicular to the Z direction are defined as the X direction and the Y direction. The above directional definitions are only used to describe the relative positional relationship and cooperation method between the components, and do not constitute a limitation on the actual installation direction of the base box. When the base box is installed on the wall, the Z direction corresponds to the horizontal direction; when the base box is installed on the ceiling, the Z direction corresponds to the vertical direction; when the base box is installed on furniture board or the ground, the Z direction can correspond to any angle. Regardless of the actual installation direction of the base box, the relative positional relationship and cooperation method between the components described in this invention remain unchanged. The directional expressions such as "top surface", "bottom surface", "front", and "back" appearing in this invention specification are all based on the installation state of the base box facing the outside of the mounting base surface in the Z direction, and are only used to describe the relative positional relationship between the components, and do not constitute a limitation on the absolute direction.

[0084] Dimensional Values: The specific dimensional values ​​(such as 95mm×95mm base box specifications, 79mm×79mm electrical panel specifications, 10mm flange distance, etc.) and range values ​​(such as tile thickness 7-9mm, finished paint thickness 8-12mm, etc.) appearing in this specification are exemplary values ​​of preferred embodiments, used to illustrate the technical principles and implementation methods of this invention, and do not constitute a limitation on the scope of protection of this invention. Those skilled in the art can select appropriate dimensional parameters according to actual engineering needs under the guidance of the technical concept of this invention.

[0085] The meaning of "flush": In this invention, "flush" means that the top edge (27) of the cover assembly (2) is on the same plane as the finished surface (42) and the top surface of the electrical panel (33), achieving an installation effect with no obvious height difference in appearance. Considering the unavoidable factors such as material shrinkage and construction errors in actual construction, "flush" should be understood as approximately flush within a reasonable construction tolerance range, rather than coplanar in an absolute geometric sense.

[0086] The meaning of "detachable connection": The "detachable connection" in this invention refers to a connection method that can be repeatedly disassembled and assembled without damaging the connecting parts, including but not limited to snap-fit ​​connection, screw connection, plug-in connection, etc., and is not limited to a specific connection structure. Those skilled in the art can select an appropriate connection method according to actual needs.

[0087] Relationship between embodiments and claims: In the context of this invention, "one embodiment," "an embodiment," or "some embodiments" refers to a feature, structure, or characteristic related to at least one embodiment of the invention. Multiple mentions in different locations in the specification do not necessarily refer to the same embodiment. The specific installation processes, material selections, and construction sequences described in the embodiments are illustrative and do not constitute a limitation on the scope of protection of this invention. In actual construction, those skilled in the art can make appropriate adjustments to the above processes, materials, and sequences without departing from the technical concept of this invention.

[0088] Component Interchangeability Description: In the base box series described in this invention, the module cavity (15), guide structure (12), and support structure (16) of each specification base box are identical, allowing the same electrical module (3) to be interchangeably installed between base boxes of different specifications. The above description of interchangeability applies to the series specifications defined in this invention, and does not preclude appropriate extensions or modifications by those skilled in the art based on this description.

[0089] Those skilled in the art may make various modifications, improvements and corrections to this invention, and such modifications, improvements and corrections are all within the spirit and scope of the embodiments of this invention within the scope of the technical concept of this invention.

Claims

1. An embedded flush modular electrical connector base box, used to fix an electrical module to an opening in a mounting base surface, characterized in that, The Z-direction is defined as the insertion and removal direction of the electrical module (3) relative to the base box body (1), and the X-direction and Y-direction are defined as two mutually perpendicular directions in a plane perpendicular to the Z-direction; the base box includes: The bottom box body (1) has at least one module cavity (15), the opening of the module cavity (15) faces the outside of the mounting base surface, and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass into the module cavity (15). The guide structure (12) is set on the inner wall of the module cavity (15) and integrally formed with the bottom box body (1). It is used to slide with the electrical module mating part (31) to realize the positioning of the electrical module (3) in the X and Y directions. The mounting flange (11) extends outward from the side wall of the base box body (1) and covers the entire substrate area of ​​the mounting base opening edge; The support structure (16) is located inside the module cavity (15) and is integrally formed with the bottom box body (1) for detachable connection with the electrical module bridge component (32); The cover assembly connection structure (14) is provided at the top opening edge of the bottom box body (1) for detachable connection with the cover assembly (2); The cover assembly (2) is detachably connected to the bottom box body (1) via the cover assembly connection structure (14), and has an opening (26) through which the power supply module (3) passes. After installation, its top edge (27) is flush with the finished surface (42).

2. An embedded flush modular electrical connector base box, used to fix an electrical module to an opening in a mounting base surface, characterized in that, The Z-direction is defined as the insertion and removal direction of the electrical module (3) relative to the base box body (1), and the X-direction and Y-direction are defined as two mutually perpendicular directions in a plane perpendicular to the Z-direction; the base box includes: The bottom box body (1) has at least two adjacent module cavities (15), each module cavity (15) has an opening facing the outside of the mounting base surface, and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass through the module cavity (15); a through cavity (19) is provided between adjacent module cavities (15), the through cavity (19) is connected to each module cavity (15), and is used to accommodate wires and parallel connectors; The guide structure (12) is set on the inner wall of each module cavity (15) and integrally formed with the bottom box body (1). It is used to slide with the corresponding electrical module mating part (31) to realize the positioning of each electrical module (3) in the X and Y directions. The mounting flange (11) extends outward from the side wall of the base box body (1) and covers the entire substrate area of ​​the mounting base opening edge; The support structure (16) is located in each module cavity (15) and is integrally formed with the bottom box body (1) for detachable connection with the corresponding electrical module bridge (32); The cover assembly connection structure (14) is provided at the top opening edge of the bottom box body (1) for detachable connection with the cover assembly (2); The cover assembly (2) is detachably connected to the base box body (1) via the cover assembly connection structure (14), and has openings (26) for each electrical module (3) to pass through. After installation, its top edge (27) is flush with the finished surface (42).

3. An embedded flush modular electrical connector base box, used to fix an electrical module to an opening in a mounting base surface, characterized in that, The Z-direction is defined as the insertion and removal direction of the electrical module (3) relative to the base box body (1), and the X-direction and Y-direction are defined as two mutually perpendicular directions in a plane perpendicular to the Z-direction; the base box includes: The bottom box body (1) has at least one module cavity (15), the opening of the module cavity (15) faces the outside of the mounting base surface, and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass into the module cavity (15). The guide structure (12) is set on the inner wall of the module cavity (15) and integrally formed with the bottom box body (1). It is used to slide with the electrical module mating part (31) to realize the positioning of the electrical module (3) in the X and Y directions. The mounting flange (11) extends outward from the side wall of the base box body (1) and covers the entire substrate area of ​​the mounting base opening edge; The support structure (16) is located inside the module cavity (15) and is integrally formed with the bottom box body (1) for detachable connection with the electrical module bridge component (32); The cover (2) is integrally formed with the bottom box body (1) and has an opening (26) through which the power supply module (3) passes. Its top edge (27) is flush with the finished surface (42).

4. An embedded flush modular electrical connector base box, used to fix an electrical module to an opening in a mounting base surface, characterized in that, The Z-direction is defined as the insertion and removal direction of the electrical module (3) relative to the base box body (1), and the X-direction and Y-direction are defined as two mutually perpendicular directions in a plane perpendicular to the Z-direction; the base box includes: The bottom box body (1) has at least two adjacent module cavities (15), each module cavity (15) has an opening facing the outside of the mounting base surface, and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass through the module cavity (15); a through cavity (19) is provided between adjacent module cavities (15), the through cavity (19) is connected to each module cavity (15), and is used to accommodate wires and parallel connectors; The guide structure (12) is set on the inner wall of each module cavity (15) and integrally formed with the bottom box body (1). It is used to slide with the corresponding electrical module mating part (31) to realize the positioning of each electrical module (3) in the X and Y directions. The mounting flange (11) extends outward from the side wall of the base box body (1) and covers the entire substrate area of ​​the mounting base opening edge; The support structure (16) is located in each module cavity (15) and is integrally formed with the bottom box body (1) for detachable connection with the corresponding electrical module bridge (32); The cover (2) is integrally formed with the bottom box body (1) and has openings (26) for each electrical module (3) to pass through. Its top edge (27) is flush with the finished surface (42).

5. A series of base boxes adaptable to various mounting base thicknesses, characterized in that: The system includes at least two base boxes according to any one of claims 1 to 4, wherein the mounting flange (11) of each base box is located at a different position in the Z direction on the side wall of the base box body (1), and corresponds to different preset mounting base thicknesses; the module cavity (15), guide structure (12) and support structure (16) of each base box are of the same specifications, so that the same electrical module (3) can be interchanged between different base boxes in the base box series.

6. The bottom box according to any one of claims 1 to 4, characterized in that: The guide structure (12) extends along the Z direction on the inner wall of the module cavity (15), with one end connected to the bottom plate of the base box body (1) and the other end suspended in the air facing the opening of the module cavity (15). The electrical module (3) can be pushed into the guide structure (12) along the Z direction. A sliding fit pair is formed between the guide structure (12) and the electrical module mating part (31). The sliding fit pair includes the fit of a convex rail and a concave rail. The convex rail can be set on one side of the guide structure (12) or one side of the electrical module mating part (31), and the concave rail is set on the corresponding other side. The two cooperate with each other to realize the positioning of the electrical module (3) in the X and Y directions. A wire receiving and guiding space (112) is formed between the guide structure (12) and the inner wall of the module cavity (15).

7. The bottom box according to claim 6, characterized in that: The guide structure (12) has a screw hole (13) at one of its suspended ends for fixing a traditional 86-type electrical panel. The screw hole (13) does not affect the sliding mating surface of the guide structure (12), thus achieving backward compatibility with the traditional 86-type electrical panel installation method.

8. The bottom box according to claim 1 or 2, characterized in that: The cover connection structure (14) includes at least two engaging grooves on opposite sides of the top opening edge of the bottom box. The engaging grooves are symmetrically arranged with a straight line perpendicular to the Z direction as the axis of symmetry. The cover (2) can be rotated 180° around the axis of symmetry and installed in the bottom box in two different orientations.

9. The bottom box according to claim 1 or 2, characterized in that: The cover assembly (2) includes a cover body (21), an isolation frame (22), a bottom box positioning protrusion frame (25), and a connecting buckle (24); the cover body (21) has an opening (26) through which the electrical module (3) passes; the isolation frame (22) is located on the top surface of the cover body (21) and protrudes around the opening (26) along the direction of the electrical module being pulled out; the bottom box positioning protrusion frame (25) is located on the side of the cover body (21) facing the bottom box opening and cooperates with the inner wall of the bottom box cavity to achieve positioning in the X and Y directions; the connecting buckle (24) is located on the side of the cover body (21) facing the bottom box opening and engages with the cover assembly connection structure (14); the top edge (27) of the isolation frame (22) is flush with the finished surface (42); after the electrical module (3) is pushed in, the top surface of the electrical panel (33) is flush with the top edge (27) of the isolation frame (22).

10. The bottom box according to claim 3 or 4, characterized in that: The cover assembly (2) is integrally formed with the bottom box body (1), including the cover plate body (21) and the isolation frame (22); the cover plate body (21) has an opening (26) through which the electrical module (3) passes; the isolation frame (22) is located on the top surface of the cover plate body (21), protruding around the opening (26) along the direction of the electrical module being pulled out, and its top edge (27) is flush with the finished surface (42); after the electrical module (3) is pushed in, the top surface of the electrical panel (33) is flush with the top edge (27) of the isolation frame (22).

11. The bottom box according to claim 9 or 10, characterized in that: The isolation frame (22) forms an isolation cavity around the opening (26). During the installation base surface finishing construction, the electrical panel (33) is isolated from the installation base surface curing material to prevent mortar, putty or paint and other curing materials from contacting and bonding the electrical panel (33). After the construction is completed, the electrical module (3) together with the electrical panel (33) is pushed into the bottom box. The electrical panel (33) is accommodated in the isolation cavity. The electrical module (3) can be pulled out as a whole at any time.

12. The bottom box according to claim 9 or 10, characterized in that: The shape of the isolation frame (22) and the opening (26) matches the shape of the corresponding electrical panel (33) and electrical module (3), including square, round or other irregular shapes, to realize the insertion of different shaped electrical modules (3) into the bottom box, and the connection and transition between the corresponding electrical panel (33) and the mounting base.

13. The bottom box according to claim 9 or 10, characterized in that: The isolation frame (22) recedes outward near the inner edge of the opening (26) to form a step (23); the electrical module (3) is provided with a support part (34) corresponding to the step (23). When the electrical module (3) is pushed in, the support part (34) presses against the step (23) to achieve the support and positioning of the electrical module (3) in the Z direction. The receding distance of the step (23) is adapted to the width of the support part (34) to achieve the support and positioning of the electrical module (3) in the X and Y directions; the step (23) and the support part (34) are axially pressed together. The support can be stably supported without the need for an interference fit between the outer wall of the support part (34) and the inner wall of the opening (26), thereby ensuring smooth insertion and removal of the electrical module (3) and reducing the processing accuracy requirements of the relevant mating surfaces. When the material of the step (23) and the support part (34) is transparent or semi-transparent, the light (36) emitted by the light-emitting element (35) of the electrical module is conducted through the support part (34) to the step (23), and then through the inner edge of the isolation frame (22) to the top edge (27) to pass through, forming the light-emitting outline around the electrical panel (33).

14. The bottom box according to claim 13, characterized in that: The cover (2) is made of transparent, semi-transparent or opaque colored material; when the material is transparent or semi-transparent, the light (36) emitted by the light-emitting element (35) of the electrical module is conducted through the support part (34) to the step (23), and then through the inner edge of the isolation frame (22) to the top edge (27) to pass through, forming the light-emitting outline around the electrical panel (33); when the material is opaque colored material, it forms a customized match in color or texture with the mounting base.

15. The bottom box series according to claim 5, characterized in that: The cover assembly (2) of each bottom box in the bottom box series includes a cover body (21) and an isolation frame (22). The cover body (21) has an opening (26) through which the electrical module (3) passes. The isolation frame (22) is located on the top surface of the cover body (21) and protrudes around the opening (26) along the direction of the electrical module being pulled out. The isolation frame (22) is recessed outward near the inner edge of the opening (26) to form a step (23). The support part (34) on the electrical module (3) is pressed onto the step (23) to achieve support and positioning. The isolation frame (22) and the step (23) of each bottom box in the bottom box series are of the same specifications, so that electrical modules (3) with the same support part (34) can be interchanged and installed in the bottom box series.

16. The bottom box according to any one of claims 1 to 4, characterized in that: The support structure (16) has a positioning part (18) for positioning the electrical module bridge (32) in the X and Y directions; the electrical module bridge (32) is detachably connected to the bottom box body (1) through the support structure (16), the support structure (16) is provided with an electrical module bridge mounting screw hole (17), and the electrical module bridge (32) is fixedly connected to the mounting screw hole (17) by screws; a wire accommodating space is formed between the electrical module bridge (32) and the bottom surface of the bottom box; electrical module bridges (32) with different functions can be directly replaced without disassembling the bottom box body (1), so that the same bottom box body (1) can be adapted to electrical modules (3) with different functions.

17. The bottom box according to any one of claims 1 to 4, characterized in that: The Z-direction position of the mounting flange (11) on the side wall of the bottom box body (1) is set according to the preset thickness of the mounting base plate. When the mounting flange (11) is attached to the back of the mounting base, the top edge (27) of the cover (2) and the finished surface (42) are on the same plane, so that the cover (2) is flush with the mounting base and no additional adjustment is needed to the position of the bottom box.

18. The bottom box according to claim 2 or 4, characterized in that: The cross-sectional area of ​​the through cavity (19) is sufficient to accommodate multiple wires and parallel connectors; the through cavity (19) is connected to the bottom of each module cavity (15), and the wires can turn within the through cavity (19) and enter any adjacent module cavity (15).

19. A method for in-situ finishing installation of an embedded flush modular electrical connector back box, the method using an embedded flush modular electrical connector back box, with the insertion and removal direction of the electrical module (3) relative to the back box body (1) as the Z direction, and two mutually perpendicular directions in a plane perpendicular to the Z direction as the X and Y directions; the back box includes: The bottom box body (1) has at least one module cavity (15), and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass through the module cavity (15); the mounting flange (11) extends outward from the side wall of the bottom box body (1); the cover (2) is integrally formed with the bottom box body (1) or detachably connected to the bottom box body (1) through the cover connection structure (14), and after installation, its top edge (27) is flush with the finished surface (42); the feature is that it includes the following steps: Step 1: Determine the position of the finished surface on the mounting base (4) and pop up the layout reference line; Step 2: Drill mounting holes on the mounting base surface (4); Step 3: Apply mortar or adhesive material to the back of the mounting flange (11) and around the bottom box, push the bottom box into the mounting hole, so that the cover (2) is located on the front side of the mounting base (4), and the mounting flange (11) is pressed against the base surface around the mounting hole; Step 4: Press and adjust the bottom box so that the top edge (27) of the cover part (2) is aligned with the layout reference line; Step 5: Complete the construction of the finishing leveling layer (41) so that the finished surface (42) is flush with the top edge (27) of the cover assembly (2); Step 6: Introduce the wires from the inlet (111) into the module cavity (15) and connect them; Step 7: Push the electrical module (3) into the module cavity (15), and make the electrical panel (33) flush with the top edge (27) and the finished surface (42) of the cover (2) to complete the installation.

20. A method for installing an embedded flush modular electrical connector back box, the method using an embedded flush modular electrical connector back box, wherein the insertion and removal direction of the electrical module (3) relative to the back box body (1) is defined as the Z direction, and two mutually perpendicular directions in a plane perpendicular to the Z direction are defined as the X and Y directions; the back box includes: The bottom box body (1) has at least one module cavity (15), and the side wall of the bottom box body (1) is provided with a wire inlet (111) for external wires to pass through the module cavity (15); the mounting flange (11) is formed by extending outward from the side wall of the bottom box body (1), and the Z-direction position of the mounting flange (11) on the side wall of the bottom box body (1) matches the thickness of the plate mounting base surface; the cover (2) is integrally formed with the bottom box body (1) or detachably connected to the bottom box body (1) through the cover connection structure (14), and after installation, its top edge (27) is flush with the front of the plate mounting base surface; the feature is that it includes the following steps: Step 1: Drill mounting holes on the mounting base surface (44) of the plate; Step 2: Insert one end of the cover (2) of the bottom box body (1) into the mounting hole from the back (45) of the plate mounting base, so that the cover (2) protrudes from the front of the plate and the mounting flange (11) is located on the back side of the plate. Step 3: Place the plate with the front side facing a reference plane (43) so that the top edge (27) of the cover (2) is aligned with the reference plane (43); the front side (42) of the plate mounting base is in contact with the reference plane (43). Step 4: In the aligned state, inject adhesive material between the mounting flange (11) and the back side (45) of the plate mounting base to bond and fix the mounting flange (11) and the back side (45) of the plate mounting base; Step 5: Install the bonded and fixed panels, along with the base box, to the installation position; Step 6: Introduce the wires from the inlet (111) into the module cavity (15) and connect them; Step 7: Push the electrical module (3) into the module cavity (15), and make the electrical panel (33) flush with the top edge (27) of the cover (2) and the front (42) of the plate mounting base to complete the installation.

Images