Precast Cable Routing Block With Adaptable EV Charger Fastening
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Solution Overview
Problem
Existing methods for routing underground electrical power cables to above-ground installations, such as electric vehicle charging stations, are inefficient, requiring specialized installation, deep trenches, and lack flexibility in fastening arrangements, while traditional concrete bases are time-consuming and prone to variability and damage during maintenance.
Innovation Solution
A preformed block with integrated conduits and a removable adaptor plate allows for routing cables without trenching, providing a stable base and adaptable fastening, enabling quick installation and maintenance without drilling into the block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional concrete bases are used, then a solid base supporting the electrical installation is provided, but the installation process is time-consuming and requires drilling holes which reduces concrete integrity
Solution Approach 1:
The base is divided into multiple precast concrete blocks with individual hollow cores, replacing the traditional monolithic concrete base. This segmentation allows for faster assembly without curing time while maintaining structural strength through the interlocking blocks and grout injection into hollow cores.
Solution Approach 2:
The concrete blocks are precast with embedded fastening arrangements (nyloc nuts, threaded rods, or tapcon screws) before installation. This preliminary action eliminates the need for drilling holes during installation, preserving concrete integrity while reducing installation time.
2Ease of operation
If standard CMUs with vertical holes are used, then cables can be routed through the block, but a deep trench is required which disturbs ground stability and requires specialized installation
Solution Approach 1:
Instead of routing cables only through vertical holes from below (one dimension), the invention provides multiple access points including side openings and top openings (multiple dimensions). This allows cables to be routed from the side or top, eliminating the need for deep trenches and maintaining ground stability.
Solution Approach 2:
The precast blocks provide multiple functions: structural support, cable routing through various openings (side, top, front), and integrated fastening arrangements. This multi-functionality eliminates the need for specialized installers and simplifies the overall installation process.
3Strength
If fastening arrangements are drilled into the concrete block, then the electrical installation can be securely attached, but the concrete integrity is reduced and the configuration cannot be changed later
Solution Approach 1:
Fastening arrangements are pre-installed in the concrete blocks during manufacturing, with different configurations available (nyloc nuts, threaded rods, tapcon screws). This allows secure attachment while preserving the option to choose different fastening types and configurations based on installation requirements.
Solution Approach 2:
The fastening arrangement is designed to be changeable and adaptable. Different fastening types can be selected based on the electrical installation requirements, and the system allows for future modifications without compromising concrete integrity, as the adaptability is built into the block design itself.
4Strength
If wet concrete is used to form the base, then a solid foundation is created, but the process is limited to favorable weather conditions and requires 24-48 hours curing time
Solution Approach 1:
The base is segmented into precast concrete blocks that can be manufactured under controlled conditions and assembled quickly on-site. This eliminates the weather-dependent curing process while maintaining the strength benefits of concrete through the precast blocks and grout injection method.
Solution Approach 2:
The concrete blocks are precast with all necessary features (hollow cores, embedded fastening arrangements, openings for cables) before installation. This preliminary preparation eliminates on-site curing time and allows immediate assembly, dramatically improving installation productivity regardless of weather conditions.
Data Source
AI summary
A preformed block is used for housing and routing electrical power cables, and comprises a central cavity. At least two adjacent faces of the block have an opening which connects to the central cavity. Electrical power cables can thus be routed within the block between those openings, from a side face (leading to a trench) to the top face (leading to an electrical installation on top). There is also provided an electric vehicle charging station using the precast block and a method of casting a block.