Document2-16/07/2014 ELECTRICAL WIRING ACCESSORIES AND RELATED PRODUCTS The present invention relates to electrical wiring accessories and the like, such as power outlets, switches, and power boards. 5 Switched power outlets for wiring into a mains supply typically comprise one or more outlet sockets, a rocker switch associated with each outlet and possibly one or more further switches for controlling external devices, all being integrated into a single unit consisting of a plastic base carrying metal components which form terminals for connection to the 10 mains, and where applicable, terminals for connection to external devices, socket insertion contacts for receiving external plugs, and switch contacts. To facilitate mass manufacture, many of these components are stamped from thin metal sheet for example of copper, brass or other alloy assembled onto the base. Figures 1 to 3 show a typical switched power socket comprising two sets of sockets with associated rocker switches for controlling 15 power to the sockets; Figures 2 and 3 show the structure within the interior of the unit with the assembled electrical components including socket insertion contacts, stationary switch contacts, a pivoting rocker switch contact plate moved by the rocker switch (shown installed in Figure 2 and removed in Figure 3), terminals for connection to the mains wiring, and conduction rails electrically connecting the various components. It will be 20 seen from Figures 2 and 3 that the conduction rails and other components, apart from the terminals, are pressed from metal sheet material to form series of integral, electrically connected, parts. The terminals are in the form of sleeves crimped, soldered, welded or otherwise connected possibly with the use of a mechanical connector to the conduction rails and carry wiring clamp screws accessible from the rear side of the unit. 25 What is shown in Figures 2 and 3 is conventional although it is to be understood that the particular shape and configuration of the metal conduction rails can vary significantly from that shown. The particular layout is essentially a matter of design choice determined by manufacturing and cost considerations. 30 Internal structure adopting the principles discussed above is also used in a wide range of other wiring accessories such as single or multiple outlets, non-switched outlets, and Document2-16/07/2014 -2 switches, and also in related products such as switched or non-switched power boards. The present invention relates to modifications to the manufacturing process of such products with a view to providing improved reliability of the finished product. 5 In accordance with the invention there is provided an electrical component in the form of a wiring accessory or power board wherein socket insertion contacts when present and/or switch contacts when present and/or conduction rails when present are of stamped metal strip, and contact zones which involve a movable mechanical contact with another 10 component to make or break an electrical connection are plated in part or in their entirety with an electrically conductive material, and/or terminals or other zones when present for connection of external wiring are plated in part or in their entirety with an electrically conductive material. 15 Advantageously, when the component includes one or more rocker switches, wherein the fixed contact zones and the contact zones of the rocker switch plate are plated in part or in their entirety. Advantageously, when the component includes one or more sets of socket insertion 20 contacts, these are plated at least in the part contacted by a plug pin when inserted into the socket. A preferred embodiment of the invention will now be described by way of example only. 25 In accordance with the preferred embodiment of the invention at least some, and preferably all, of the electrical contact zones in the product are plated. By contact zones in this context, there is meant zones which involve a movable mechanical contact with another component to effect an electrical connection, in particular the socket insertion contacts, zones forming the fixed rocker switch contacts, and the movable rocker switch plate. The 30 plating is designed to improve one or more of the following: resistance to environmental corrosion; contact wear; reduction in carbonisation leading to high resistance deposits. The selected plating material is, of course, electrically conductive and will be determined Document2-16/07/2014 -3 by the improvements required and by the environment in which the product is intended to be used; for example whether the product is designed so as to be suitable for marine use. By way of example, suitable plating materials for conduction rails,conduit rails, contacts or terminal contacts include rhodium, palladium or alloys which incorporate rare/precious 5 earth materials in various combinations. Such plating materials may be used in conjunction with common materials such as silver, copper or alloys typically used in electrical applications. Figure 4 is a view similar to Figure 3 but showing in darker shading the corresponding 10 contact zones which can be plated in accordance with the invention. It will be noted from this that the entirety of the insertion contacts is plated, the fixed switch contact zones are plated and substantially the entirety of the rocker switch plate is plated. It is however to be noted that the extent of the plating might be less than that shown provided that the plating adequately covers the zones at which a movable mechanical contact takes place; as such, 15 for example, only part of the fixed switch contact zones and/or only part of the rocker switch plate may be plated. This selected plating is achieved by a so-called precision plating process and the extent to which zones outside of the immediate areas of contact need to be plated will vary according to the accuracy which can be obtained within the range of tolerance achievable by a particular plating process. At the very least it is of 20 course essential that the plating will cover at least the critical areas. While precision plating selected zones is preferred for cost considerations in order to minimise the amount of plating material required, it would nevertheless be feasible to plate the entirety of the pressed metal components to improve production efficiency particularly 25 in larger scale production. Although in the embodiment described all of the switch contact zones and socket insertion contacts are plated in the manner discussed, depending on the objectives required by the plating it is in principle feasible to plate only some of the contact zones where there is 30 particular need for an improvement in functionality such as corrosion resistance, wear resistance and so forth.
Document2-16/07/2014 -4 Plating may also be needed at terminals and other zones at which external wiring is connected to the accessory, typically by means of a screwed connection. Plating in those zones can reduce corrosion and prevent "hot spots" forming. This effect can often arise when used in salty environments where conventional copper/alloy terminals corrode and 5 can cause over-heating. By way of example, the terminals shown in Figure 4 likewise in darker shading are plated in whole or in part according to the principles discussed earlier. It is also to be noted that while plating may be provided in all of the contact zones whether movable (such as switch or socket) or fixed (such as terminals), depending on the function 10 the plating is to perform and which will depend on the nature of the accessory and/or the environment in which it will be used, plating may be applied only to some of the contact zones. Although the invention in its preferred embodiment has been particularly described in 15 relation to a switched double socket outlet, the principles of the invention described herein are applicable to a wide range of other wiring accessories such as single or multiple power outlets, light switches, gang switches, and power boards whether switched or unswitched.