VINYL SHEET FINISHING ON DISTRIBUTION BOARD
FIELD OF INVENTION:
[001] The present subject matter described herein, in general, relates to field of distribution boards, and in particularly relates to vinyl film/sheet finishing on distribution board. 5
BACKGROUND AND PRIOR ART:
[002] Powder coating is a process of coating metal with a plastic finish applied in powder form and baked to a fluid state to bond it to the metal surface. The coating is typically applied electrostatically and is then cured under heat to allow it to flow and form a “skin”. The powder may be a thermoplastic or a thermoset 10 polymer. It is usually used to create a hard finish that is tougher than conventional paint. One typical example of prior art design is shown in figure 1.
[003] There are two main categories of powder coating: thermosets and thermoplastics. The thermosetting variety incorporates a cross-linker into the formulation. When the powder is baked, it reacts with other chemical groups in 15 the powder to polymerize and improving the performance properties. The thermoplastic variety with addition of process aids does not undergo any additional actions during the baking process, but rather only flows out into the final coating.
[004] Earlier, powder coating used as a decorative finishing process resulted in 20 rework and wastage of material as the process needs to apply more than once to achieve uniform finishing with adequate deposition of powder. Powder coating has major drawbacks that it is not uniformly deposited at the edges of metal sheet due to lower surface area and metal sheet of the distribution always exposed to corrosion at the edges. This also resulted in field failure of distribution board. 25 Further, fumes of powder floating in air require more safety to workers and adjacent environment.
[005] US Publication No.: US5274528 relates to an assembly for both distributing and limiting electric current. The bus bars each have a general U-
3
shaped flat configuration with two rows of offset terminals located at different heights. The bus bars are comprised of metal conductors having an insulative cover. In a preferred embodiment, the insulative cover is a baked-on epoxy. However, a vinyl dip could also be used.
[006] Publication No.: US20130329765 relates to an infrared transmissive 5 protective cover, a method for manufacturing the same, and a monitoring method using the same. In order to protect components such as high-voltage terminals, the protective cover may be used as a protective cover that protects the entire panel such as distribution boards, and may be used as a protective cover that protects only a portion that requires monitoring by infrared rays. Polypropylene resin may 10 herein be a homopolymer of propylene, or may be a copolymer of propylene and another comonomer copolymerizable with propylene (e.g., a-olefin such as ethylene, 1-butene, 1-hexene and 1-octene; vinyl acetate; vinyl alcohol; etc.
[007] Publication No.: CN203026798 (U) relates to an anti-corrosion epoxy resin compound power distribution box. The anti-corrosion epoxy resin compound 15 power distribution box is characterized in that a vinyl resin bonding.
[008] Publication No. CN202384712 (U) relates to a new distribution box side door. The novel door facade provided by the utility model overcomes defects of heavy iron products and flammable PVC (Poly Vinyl Chloride) is flexible and convenient to manufacture, has the advantages of economical and practical 20 manufacturing cost and good corrosion-resistant ageing effect.
[009] Publication No US7781517 relates to flame retardant rubber modified aromatic vinyl composition. The polymer compositions are molded into a housing or body of electronic or non-electronic devices. Examples of electrical and non-electrical, in which a molded article made of the blend of the composition 25 according to embodiments of the invention are used, include printers, computers, word processors, keyboards, personal digital assistants (PDA), telephones, mobile phones, cameras, camera carrying devices, bags, table surfaces, laminates, facsimile machines, copy machines, electronic cash registers (ECR), desk-top electronic calculators, PDAs, cards, stationery holders, washing machines, 30
4
refrigerators, vacuum cleaners, microwave ovens, lighting equipment, irons, TV, VTR, DVD players, video cameras, radio cassette recorders, tape recorders, mini disc players, CD players, speakers, liquid crystal displays, MP3 players, and electric or electronic parts and telecommunication equipment, such as connectors, relays, condensers, switches, printed circuit boards materials, coil bobbins, 5 semiconductor sealing materials, electric wires, cables, transformers, deflecting yokes, distribution boards, clocks, watches, and the like.
[0010] Publication No US7781516 relates to a flame retardant polymer composition comprising a rubber modified aromatic vinyl resin employing a cyclic alkyl phosphate compound. Examples of electrical devices, in which a 10 molded article made of the blend of the composition according to embodiments of the invention are used, include printers, computers, word processors, keyboards, personal digital assistants (PDA), telephones, mobile phones, cameras, facsimile machines, copy machines, electronic cash registers (ECR), desk-top electronic calculators, PDAs, cards, stationery holders, washing machines, refrigerators, 15 vacuum cleaners, microwave ovens, lighting equipment, irons, TV, VTR, DVD players, video cameras, radio cassette recorders, tape recorders, mini disc players, CD players, speakers, liquid crystal displays, MP3 players, and electric or electronic parts and telecommunication equipment, such as connectors, relays, condensers, switches, printed circuit boards materials, coil bobbins, 20 semiconductor sealing materials, electric wires, cables, transformers, deflecting yokes, distribution boards, clocks, watches, and the like.
[0011] Publication No US7838593 relates to a flame retardant molding composition includes a rubber modified aromatic vinyl resin, a polyphenylene ether resin, and a cyclic phosphonate ester compound. A shaped article and an 25 electronic device can be made from the flame retardant molding composition.
[0012] Publication No US7723429 relates to a polymer composition includes a rubber-modified aromatic vinyl resin and a cyclic phosphonate ester compound. Embodiments of the composition demonstrate good impact strength, flame retardancy, heat resistance. Some embodiments additionally demonstrate moisture 30
5
resistance and low heat sag. A shaped article and an electronic device can be made from the flame retardant polymer composition. Examples of electrical devices in which a molded article made of the blend of the composition according to embodiments of the invention include printers, computers, word processors, keyboards, personal digital assistants (PDA), telephones, mobile phones, facsimile 5 machines, copy machines, electronic cash registers (ECR), desk-top electronic calculators, PDAs, cards, stationery holders, washing machines, refrigerators, vacuum cleaners, microwave ovens, lighting equipment, irons, TV, VTR, DVD players, video cameras, radio cassette recorders, tape recorders, mini disc players, CD players, speakers, game machines, liquid crystal displays, MP3 players, and 10 electric or electronic parts and telecommunication equipment, such as connectors, relays, condensers, switches, printed circuit boards materials, coil bobbins, semiconductor sealing materials, electric wires, cables, transformers, deflecting yokes, distribution boards, clocks, watches, and the like.
[0013] Publication No US7910655 relates to a polymer composition including a 15 polyarylene sulfide resin, a olefinic graft copolymer, and a fluorinated polyolefin resin. Some embodiments may additionally comprise an epoxy compound and/or a filler. In some embodiments, the compositions have good flame retardancy, impact strength, and flexural strength.
[0014] Application No. 2412/CHENP/2014 relates to power supply system, the 20 electric-motor vehicle and the power equipment are electrically connected to each other with a cable. Electric power is supplied to a socket not illustrated from the distribution board and a load can operate with AC power supplied from the distribution board by connection to the socket.
[0015] Publication No. CN103060860 relates to an electroplating solution for acid 25 copper-plating for a circuit board as well as a preparation method and an application method for the same. The electroplating solution is characterized in that a home-made synthesised levelling agent is added, and the levelling agent is matched with water-soluble copper salt, sulphuric acid, a brightening agent, chloride ions, a gloss agent and a surfactant to form the electroplating solution. 30
6
The home-made levelling agent is one or more of the copolymer of N-vinyl imidazole onium salt and propenyl esters, and the polymer of N-vinyl imidazole and epoxides.
[0016] Publication No. 20030114606 relates to a flame-retardant epoxy resin composition, a molded article thereof and an electronic part. Electronic parts 5 described above are subjected to any suitable electrical treatment and machining to follow and further used in the following applications, which are, for example, a printer, a computer, a word processor, a key board, a compact information terminal equipment (PDA), a telephone, a portable telephone, a facsimile, a copier, an electronic cash register (ECR), a hand held calculator, an electronic 10 notepad, an electronic dictionary, a card, a holder, an administrative and OA equipment including stationary, a washer, a refrigerator, a cleaner, a microwave oven, a lighting fixture, a game machine, an iron, home electrical appliance such as electric foot warmer, a television set, VTR, a video camera, a radio cassette player, a tape recorder, a mini-disk player, a CD player, a DVD player, a speaker, 15 AV equipment such as a liquid crystal display, an EL display, a plasma display and others, a connector, a relay, a capacitor, a switch, a coil bobbin, a battery, a CCD sensor, an electric wire, a cable, electrical and electronic parts such as a transformer, a motor, an antenna coil, a deflection york, a distribution board, a clock-and others, and communication equipment such as non-contact data carrier 20 package system, and others.
[0017] Publication No. 20030166812 relates to a flame retardant made of a phosphazene having a polymerizable functional group, a flame-retardant resin composition compounded with the flame retardant, a molded article and an electronic part using the flame-retardant resin composition. As actual applications, 25 there are named: in electrical, electronic and communication equipment, for example, a printer, a computer, a word processor, a key board, a personal digital assistant (PDA), a telephone, a portable telephone, a facsimile machine, a copier, an electronic cash register (ECR), a hand held calculator, an electronic notepad, an electronic dictionary, a card, a holder, an administrative and OA equipment 30
7
including stationary, home electrical appliance such as a washer, a refrigerator, a cleaner, a microwave oven, a lighting fixture, a game machine, an iron and electric foot warmer, AV equipment such as a television set, VTR, a video camera, camcorder, a radio cassette player, a tape recorder, a mini-disk player, a CD player, a DVD player, an LD player, a speaker, a liquid crystal display, and its 5 driver, an EL display, a plasma display and others, electrical and electronic parts such as a connector, a relay, a capacitor, a switch, a printed board material, a coil bobbin, a semiconductor encapsulation material, a battery and its separator or its sealing material, CCD, LED, an electric wire, a cable, a transformer, a motor, an antenna coil, a deflection york, a distribution board, a clock and others, and 10 communication equipment such as non-contact data carrier package system, a smart card/a smart tag and others.
[0018] Publication No. 20090048377 relates to a flame-retardant resin processed article for use, for example, in electric components and electronic components as a resin molded article, a coating film or a sealing agent. Specific examples of such 15 electrical or electronic component include: a receiving board; a distribution board; an electromagnetic switch; a breaker; a transformer; an electromagnetic contactor; a circuit protector; a relay; a transformer; various sensors; various motors; and semiconductor devices such as a diode, a transistor, and an integrated circuit.
[0019] Publication No.: 20090043032 relates to a flame retardant for use in a 20 resin molded article or the like and a flame-retardant resin processed article using the same. Specific examples of such electrical or electronic component include: a receiving board; a distribution board; an electromagnetic switch; a breaker; a transformer; an electromagnetic contactor; a circuit protector; a relay; a transformer; various sensors; various motors; and semiconductor devices such as a 25 diode, a transistor, and an integrated circuit.
[0020] Publication No. 20110092622 relates to a flame-retardant synthetic resin composition, which is comprised of a synthetic resin, a special phosphate compound and a layered silicate, but does not contain halogen flame retardants. Examples of synthetic resin used in the present invention are α-olefin polymers 30
8
such as polypropylene, high density polyethylene, low density polyethylene, straight chain low density polyethylene, polybutene and poly-3-methylpentene; or copolymers such as ethylene-vinyl acetate copolymers ethylene-propylene copolymers and copolymers thereof; petroleum resin, coumarone resin, polystyrene, polyvinyl acetate, acrylic resin, copolymers of styrene and/or α-5 methylstyrene with other monomers (such as maleic anhydride, phenyl maleimide, methyl methacrylate, butadiene and acrylonitrile) (for example, AS resin, ABS resin, MBS resin, heat-resistant ABS resin or the like), straight chain polyesters such as polymethylmethacrylate, polyvinyl alcohol, poly(vinyl formal), polyvinyl butyral, polyethylene terephthalate and polybutyrene terephthalate; polyamides 10 such as polyphenylene oxide, polycaprolactam and polyhexamethylene adipamide; thermoplastic resins and these blends such as polycarbonate, polycarbonate/ABS resin, branched polycarbonate, polyacetal, polyphenylene sulfide, polyurethane and cellulose resin; or biodegradable polylactic acid resin, other than thermosetting resins such as phenol resin, urea resin, melamine resin, 15 epoxy resin and unsaturated polyester resin.
[0021] Publication No. 7,851,528 relates to a flame-retardant resin processed article for use, for example, in electric components and electronic components as a resin molded article, a coating film or a sealing agent. Therefore, the resin processed article can be suitably used for an electrical or electronic component in 20 which high levels of heat resistance and flame retardance are required, and for an automobile part or an optical part, such as a member for supporting a contact of an electromagnetic switch, a breaker, or the like; a substrate such as a printed board; a package for an integrated circuit; or a housing for an electrical component. Specific examples of such electrical or electronic component include: 25 a receiving board; a distribution board; an electromagnetic switch; a breaker; a transformer; an electromagnetic contactor; a circuit protector; a relay; a transformer; various sensors; various motors; and semiconductor devices such as a diode, a transistor, and an integrated circuit.
30
9
[0022] Thus, in view of the above prior arts, it is clear that powder coating process has one or more disadvantages like it requires a greater film thickness and is difficult to achieve adequate film thickness without creating an orange peel effect. Further it is not possible to touch-up in the field with a good color match. Additionally single coat powder paints on distribution board are susceptible to 5 corrosion particularly at edges due to lower surface area; as a result improper adhesion of powder. Moreover, it takes more time as we are not able to get the required finish in one single attempt which also leads to contamination and rework.
[0023] Hence, the present invention aims to provide decorative and protective 10 vinyl film/sheet finishing on distribution board which prevents major prior art drawbacks.
OBJECTS OF THE INVENTION:
[0024] The principal objective of the present invention is to provide vinyl sheet/film finishing on distribution board which will have dual function of 15 aesthetics and protection from defects of prior arts.
[0025] Another object of the present invention is to achieve the desired finish in a single attempt with improved results.
[0026] Yet another object of the present invention is to eliminate rework and reduce wastage of material as was in case of powder coating. 20
[0027] Still another object of the present invention is to reduce sample rejections due to finishing defects.
[0028] Another object of the present invention is to provide high durability, weatherability, conformal design possibility, corrosion protective layer and ease of maintenance. 25
[0029] Yet another object of the invention is to provide a process that is easy to apply, environment friendly, and safe to operators health.
10
[0030] Another object of the invention is to provide a distribution board with large variety of finishes that replicate natural look of wood, marble, granite and leather etc.
SUMMARY OF THE INVENTION:
[0031] The present subject matter disclosed herein relates to a finishing process 5 for distribution boards in a single attempt with better results. Vinyl film/sheet provides with large variety of finishes that replicates natural look of wood, marble, granite, leather etc. These are low volatile organic compound, homogenous with uniform colours permeating every layer making them resistant to damage from scratches, dents and stains. The vinyl sheet are applied on the 10 distribution board for protecting the distribution board from scratches, dents, and corrosion.
[0032] In order to further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative 15 only but not used to limit scope of the present subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally 20 effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods in accordance with 25 embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which:
[0034] Figure 1 shows powder coated finish according to the known art;
11
[0035] Figure 2 illustrates finishing of the vinyl film/sheet on distribution board, in accordance with the present subject matter; and
[0036] Figure 3 illustrates a process for applying the vinyl film/sheet on the distribution board, in accordance with the present subject matter.
[0037] The figure depicts embodiments of the present subject matter for the 5 purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DESCRIPTION OF THE PREFERRED EMBODIMENTS: 10
[0038] The present subject matter provide vinyl film/sheet finishing on distribution board.
[0039] It should be noted that the description and figures merely illustrate the principles of the present subject matter. It should be appreciated by those skilled in the art that conception and specific embodiment disclosed may be readily 15 utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present subject matter. It should also be appreciated by those skilled in the art that by devising various arrangements that, although not explicitly described or shown herein, embody the principles of the present subject matter and are included within its spirit and scope. Furthermore, all examples 20 recited herein are principally intended expressly to be for pedagogical purposes to aid the reader in understanding the principles of the present subject matter and the concepts contributed by the inventor(s) to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions. The novel features which are believed to be characteristic of the 25 present subject matter, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures.
12
[0040] These and other advantages of the present subject matter would be described in greater detail with reference to the following figures. It should be noted that the description merely illustrates the principles of the present subject matter. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described herein, embody the 5 principles of the present subject matter and are included within its scope.
[0041] Figure 2 illustrates different vinyl film/sheet finishes on distribution board, in accordance with the present subject matter. The electrical wiring is carried out to distribute current from a single source of supply to various circuits, such an arrangement is made inside an enclosure called distribution board. 10
[0042] In the present subject matter, the decorative Vinyl film/sheet finishing on distribution board is made by calendaring process with gravure/ screen/ UV/ flexo/ digital printing on the top surface with variety of textures and back coated adhesive. The adhesives can be selected from the group of acrylate with different functional moieties such with modified urethane, acrylamide, epoxies, ethers and 15 combination thereof to enhance tack, peel and shear strength which was applied on vinyl sheet /film with applicator for better adhesive strength to metal part.
[0043] Figure 3 illustrates a process for applying the vinyl film/sheet on the distribution board, in accordance with the present subject matter. The process starts at step 300. At the step 302, fabrication part of distribution board goes 20 through the pretreatment process of phosphating. In the phosphating process, the surface of the distribution board is cleaned by emulsion to remove Oil, grease, dirt and swan from the surface. Further, rust and scale from the surface is removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying. After phosphating process, the distribution 25 board is rinsed with clean water and final rinsing is done with dilute dichromate solution and over drying.
[0044] After pretreatment of the distribution board with the phosphating process, a powder coating is applied at step 304. The powder coating makes outer surface of the distribution board smooth. At the step 306, a decorative vinyl film/sheet is 30
13
applied on the smooth powder coated distribution board. The vinyl sheet/film has the following properties, such as High weatherability, heat resistance, Moisture resistance, Low temperature resistance and improved tear resistance and tensile strength. The vinyl sheet/film is applied to a smooth and leveled outer surface of the distribution board cover using compatible adhesive for vinyl sheet /film of 5 high peel strength, high Tackiness, stain resistance with good freeze thaw stability that remains pliable. The vinyl film/sheet pasting provide better finishing with large variety of finishes in a single process which helps in avoiding rework and scrap rate. The decorative vinyl film/sheet in distribution board results in customized variety of finish with minimum rework and wastage of material while 10 making the distribution board aesthetically appealing.
[0045] The present process for making a distribution board that replicates the look of wood, marble, granite leather etc. in installation the film/sheet is applied to a smooth, leveled outer cover using appropriate adhesive with vinyl compatibility. The vinyl sheet tends to be significantly more rigid, so it is more frequently sold 15 in film/sheet and squares rather than rolls. The vinyl file/sheet sometimes used as a substitute of genuine wood as it is similar in texture to wood with a glossy topcoat.
[0046] Although embodiments for the present subject matter have been described 20 in language specific to structural features, it is to be understood that the present subject matter is not necessarily limited to the specific features described. Rather, the specific features and methods are disclosed as embodiments for the present subject matter. Numerous modifications and adaptations of the system/component of the present invention will be apparent to those skilled in the art, and thus it is 25 intended by the appended claims to cover all such modifications and adaptations which fall within the scope of the present subject matter.

We claim:
1. A distribution board having vinyl sheet finishing for protecting the distribution board from scratches, dents, and corrosion.
2. The distribution board as claimed in claim 1, wherein the vinyl sheet is applied on outer surface of the distribution board using compatible vinyl 5 adhesive.
3. The distribution board as claimed in claim 1, wherein the vinyl sheet has two layers made by calendaring process with gravure/screen/UV/flexo/digital printing on top surface with variety of textures and back coated adhesive. 10
4. The distribution board as claimed in claim 1, wherein the distribution board goes through pretreatment process of phosphating followed by powder coating and then finally decorative vinyl film/sheet transfer takes place.
5. The distribution board as claimed in claim 1, wherein the vinyl sheet has layer composition using calendared printed back coated adhesive layer of 15 poly vinyl compound over steel frame has different finishes selected from wood, leather, stone, brushed and matte or the like.
6. A process for applying vinyl sheet on distribution board, the process comprising:
Pre-treating the distribution board using phosphating process; 20
Applying powder coating on the phosphate distribution board to make surface smooth;
Applying the vinyl sheet on the smooth powder coated distribution board using adhesive.
25
7. The process as claimed in claim 6, wherein the adhesive is selected from group consisting of Polyvinyl acetate, Ethyl vinyl acetate, EVA-Modified.
15
8. The process as claimed in claim 6, wherein the vinyl sheet has two layers made by calendaring process with gravure/screen/UV/flexo/digital printing on the top surface with variety of textures and back coated adhesive.
9. The process as claimed in claim 6, wherein the vinyl sheet has two layer composition using calendared printed back coated adhesive layer of poly 5 vinyl compound over steel frame has different finishes selected from wood, leather, stone, brushed and matte or the like.