EP2793661A1

EP2793661A1 - Controls for heated liquid vessels and electrical appliances

Info

Publication number: EP2793661A1
Application number: EP12821121.6A
Authority: EP
Inventors: Antonio Gaeta; Peter Wright; Mark Sherratt; Richard LINDLEY; Paul Boundy; Mark FARLAM; Robin Moore; Richard So; Robert Hadfield
Original assignee: Otter Controls Ltd
Current assignee: Otter Controls Ltd
Priority date: 2011-12-23
Filing date: 2012-12-24
Publication date: 2014-10-29
Also published as: CN104039203B; CN203883177U; CN203272781U; JP2015502236A; CN203967372U; CN104039203A; CN204011828U; WO2013093526A1; CN204144502U; CN203218500U; CN203967432U; CN203272784U

Abstract

Controls for Heated Liquid Vessels and Electrical Appliances A substantially 360º cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector (3) and a corresponding socket connector (4), the plug connector (3) comprising a substantially central plug (530) conductor for electrical connection to a corresponding socket conductor (137L) within a substantially central socket (64) in the socket connector (4), the plug connector (3) further comprising at least second and third conductors (127, 534N) located outwardly of the substantially central plug conductor (530) each at a different radial distance from the substantially central plug conductor (530), for electrical connection to corresponding conductors (137,N, 137N) in the socket connector (4).

Description

Controls for Heated Liquid Vessels and Electrical Appliances Field of the Invention

[0001] The present invention relates to controls for heated liquid vessels and electrical appliances and components therefor. Some aspects of the invention are directed to cordless electrical appliances.

Background of the Invention

[0002] There is a constant commercial pressure in the domestic appliance industry to lower the price or reduce the costs of components for small domestic appliances.

[0003] One factor is to reduce the cost of components used in these appliances. The present inventors understand that the issue is greater than just the cost of the materials or components and have realised that there is a need to reduce the impact or cost of domestic appliances through interrelated factors, including other commercial, logistical and the environmental aspects. Invariably, reducing the mass or volume of material used in an appliance will have a positive effect on the material price of the appliance. However, there are also other aspects, for example, rework, shipping and packing whereby innovation can make great strides in reducing costs.

[0004] Another way to reduce the cost of an appliance to is to reduce the material costs of the controls and connector systems. Typically the appliances are required to be rated at above 2 kW at 240volts and perform at very high temperatures. For example the plastics used in the control and connector components are advanced engineering type plastics with very specific properties to suit the very specific safety critical requirements. Typically the plastic costs in a prior art integrated 360° control and connector account for up to 60% of the material costs of the control, therefore any initiative to reduce these costs with have a substantial effect on the costs of the components. Statements of the Invention

[0005] According to one aspect of the present invention, there is provided a substantially 360° cordless liquid heating appliance and a corresponding power base wherein the appliance comprises a thermal control mounted to a heating element and the thermal control having:

a. 360° electrical plug connector for connection to a corresponding 360° electrical socket connector in the power base;

b. a chassis for mounting the thermal control to the heating element c. an actuator in response to steam to switch off the thermal control in response to the temperature of the liquid to be heated;

d. at least one bimetallic actuator mounted on the chassis, to switch off the thermal control in response to an over temperature condition of the heating element;

e. a pivotal actuator operable to operate a switching means between at least two states; and

f. an electrical conductor, wherein the conductor having one end arranged to be mechanically and/or electrically connected to a cold tail of the heating element and a portion for cooperating with said switching means,

wherein the plug connector comprises an annular passageway for engagement with at least the socket connector and/or a portion of the power base, and said passageway having means for receiving a single resilient component to bias at least the pivotal actuator into an off state when the appliance is separated from the power base.

[0006] According to another aspect, when the appliance is engaged with said power base the resilient component may be urged away from the pivotal actuator so the pivotal actuator can operate in either the on and/or off state as required.

[0007] The resilient component may comprise one end secured to the electrical plug connector and the other end for engagement with said the electrical socket connector and/or said portion of the power base.

[0008] The resilient component may comprise a fold or other feature to prevent damage or snagging when engaging and/or disengaging with the electrical socket connector and/or said portion of the power base.

[0009] The electrical plug connector may comprise an aperture to allow the resilient component to pass therethrough and into the annular passageway for engagement with the electrical socket connector and/or portion of the power base.

[0010] The single resilient component may be arranged to force the pivotal actuator to an off position as the electrical plug connector is separated from the electrical socket connector and/or portion of the power base to switch off the appliance.

[0011] The electrical conductor is a flat electrical conductor formed from stamping of a continuous strip material. The flat electrical conductor may comprise at least one fold or twist to at least plastically deform said flat electrical conductor, whereby the at least one fold or twist provides a change in direction in at least one of the horizontal, axial, radial and/or vertical plane of the flat electrical conductor. Angular, axial, rotational and/or radial compliance may be provided between the cold tails and the flat electrical conductor. [0012] A clip may be provided for electrically and/or mechanically securing said one end of the flat electrical conductor to the cold tail, wherein contact forces for the electrically and/or mechanically connection is at least partially provided by the resilience of the clip. The clip and the flat electrical conductor are configured to provide both compliance between the cold tail and the conductor and the contact forces to electrically and/or mechanically secure the cold to the conductor, wherein the compliance includes angular, axial, rotational and/or radial compliance between the cold tail and the flat electrical conductor.

[0013] The electrical conductor may further comprise an aperture for receiving the cold tail and at least one resilient barb arranged in a radial and/or linear configuration relative to the aperture, for engaging the cold tail for mechanical and/or electrical connection. The cold tail further comprises retention means for engaging with said at least one resilient barb to retain the electrical conductor on the cold tail.

[0014] According to another aspect of the present invention, there is provided a thermal control apparatus for a liquid heating vessel having a heating element plate, the thermal control apparatus comprising a chassis for mounting to the heating element plate, the chassis having an actuator mount at one end for mounting at least one bimetallic actuator in proximity to the heating element plate, a support portion at the other end of the chassis, wherein the actuator mount and the support means are arranged to support the chassis against the heating element plate in use, and having at least one resilient portion provided between the actuator mount and the support means for resiliently supporting the chassis against the heating element plate.

[0015] Clamping means may be provided for resiliently deforming and securing the resilient portion against the heating element plate and thereby control the proximity of the actuator to the element plate. Respective surfaces of actuator mount, support portion and resilient portion for engaging and/or abutting against the heating element plate may be provided such that they are not coplanar prior to securing the resilient portion against the heating element plate.

[0016] A support for the at least one resilient portion may act as a backstop for the bimetal actuator so that the proximity of both the bimetal actuator and the backstop to the element plate are controlled by the final mounting position of the chassis. The clamping means comprises no more than two discrete clamping points.

[0017] According to another aspect of the present invention, there is provided a thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus having a connector assembly comprising: a. a main moulding having an actuator mount for mounting at least one bimetallic actuator operable to be actuated by steam; and

b. a bistable actuator having pivotally mounted on said main moulding and is operable to be actuated by said bimetallic actuator,

wherein said thermal control apparatus comprises a surface angled towards flow of the steam, for deflecting the steam flow towards the bimetallic actuator, wherein the angled surface is provided on the control or a sub base of said cordless liquid heating vessel.

[0018] According to another aspect of the present invention, there is provided a substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the socket connector comprising at least two apertures for receiving corresponding electrical conductors, and each aperture is provided with drainage means for draining liquids away from the respective apertures, wherein the power base comprises an annular skirt that functions as a weir and/or barrier in conjunction with an annular channel provided in the socket connector to contain any excess liquid and divert this liquid towards an aperture.

[0019] According to another aspect of the present invention, there is provided a substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the socket connector comprising at least two apertures for receiving corresponding electrical conductors, wherein the socket connector comprises at least one vertically extending conductor positioned externally of the at least two apertures of the socket connector. .

[0020] The at least one vertically extending conductor may be housed within an individual shroud and/or annular skirt. The power base may comprise a base cover, and the annular skirt may form a portion of the base cover.

Brief Description of the Drawings

[0021] There now follows, by way of example only, a detailed description of preferred embodiments of the present invention, with reference to the Figures identified below.

Figure 1 is a schematic cross-section of a cordless liquid heating appliance in an embodiment of the invention.

Figure 53qca is an isometric view of a heating element with a control having wires secured thereto.

Figure 53qcb is a detailed view of Figure 53qca. Figure 53qcc is a perspective of the resilient spring and wire conductor of Figures 53qca and 53qcb.

Figure 53qcd is a detailed view of an embodiment of Figure 53qcb.

Figure 53qce is a perspective of the resilient spring and wire conductor of Figure

53qcd.

Figure 53qcf is perspective view of the wire conductor with an electrical connection towards its distal end.

Figure 53qcg is a perspective view of the resilient spring connected to the wire conductor.

Figure 53qch is an isometric view of the control of Figure 53qca.

Figure 53qci is a cross sectional view through line X-X of the control of Figure

53qch.

Figure 53qcj is an exploded isometric view of the chassis and the earth ring of Figures 53qch and 53qci from above.

Figure 53qck is an exploded isometric view of the chassis and the earth ring of Figures 53qch and 53qci from below.

Figure 53qcl is a sectional view of the chassis and the earth ring of Figures 53qch to 53qck prior to engagement.

Figure 53qcm is a sectional view of the chassis and the earth ring of Figures 53qch to 53qck at the first phase of engagement.

Figure 53qcn is a sectional view of the chassis and the earth ring of Figures 53qch to 53qck at the second phase of engagement.

Figure 53qco is an isometric view of an embodiment of the earth ring.

Figure 53qcp is an isometric view of the chassis of Figure 53qch.

Figure 53qcq is a schematic view of the chassis of Figure 53qcp and a heating element plate and heat transfer plate prior to engagement.

Figure 53qcr is a schematic view of the chassis of Figure 53qcp and the heating element plate and heat transfer plate at the first phase of engagement.

Figure 53qcs is a schematic view of the chassis of Figure 53qcp and the heating element plate and heat transfer at the second phase of engagement.

Figure 53qct is a schematic view of the chassis of Figure 53qcp and the heating element plate and heat transfer plate at the third phase of engagement.

Figure 53qcu is an exploded isometric section view of the control of Figure 53qch mounted on the heating element plate, heat transfer plate and sub base. Figure 53qcv is detailed view of Figure 53qcu illustrating the sub base is secured to the control.

Figure 53qcw is an embodiment of Figure 53qcv illustrating the sub base is secured to the control.

Figure 53qcx is an exploded isometric section view illustrating an embodiment where the sub base is secured to the appliance body.

Figure 53qcy is an isometric view of a control according to an embodiment of the invention secured to a heating element.

Figure 53qcz is an isometric view of the control of Figure 53qcy from above.

Figure 53qcza is an isometric view of the control of Figure 53qcy from below.

Figure 53qczb is an exploded isometric view of the control of Figures 53qcy to

53qcza.

Figure 53qczc is a partial cut-away view of a central live conductor of the control of Figures 53qcy to 53qczb.

Figure 53qczd is an embodiment of the central live conductor of Figure 53qczc.

Figure 53qcze is an exploded isometric view of the chassis, control moulding and the earth ring of Figures 53qcy to 53qczb from below.

Figure 53qczf is an isometric view of the control of Figure 53qcy from above with the chassis removed for illustrative purpose.

Figure 53qczfa is an isometric view of the chassis of Figure 53qcz.

Figure 53qczfb is an isometric view of a variation of the control of Figure 53qcx from above.

Figure 53qczfc is an isometric view of the control of Figure 53qczfb from below. Figure 53qczfd is an isometric view of the control of Figure 53qczfb with the chassis removed for illustrative purpose.

Figure 53qczfe is an isometric view of the chassis from the control of Figure 53qczfb.

Figure 53qczff is an isometric view of a push rod guide from the control of Figure 53qczfd.

Figure 53qczfg is a perspective view of an embodiment of the resilient spring and wire conductor of Figure 53qce.

Figure 53qczfh is an exploded detail view of a variant of the resilient spring and wire conductor of Figure 53qczfg. Figure 53qczfi is an assembled of the resilient spring and wire conductor of Figure 53qczfh.

Figure 53qczfj is a detailed view of a variant of the wire conductor of Figure 53qczfh.

Figure 53qczfk is a perspective view of another variant of the resilient spring and wire conductor of Figure 53qczfg.

Figure 53qczfl is a perspective view of a variant of the resilient spring and wire conductor of Figure 53qczfk.

Figure 53qczfm is a plan view of the control of Figure 53qczfb alongside the resilient spring and wire conductor of Figure 53qczfl.

Figure 53qczfn is a perspective view of another variant of the resilient spring and wire conductor of Figure 53qczfk.

Figure 53qczfo is an exploded view of an embodiment of the resilient spring and wire conductor of with cold tail connection means and the heating plate.

Figure 53qczfp is an assembled view of the resilient spring and wire conductor and the heating plate of Figure 53qczfo.

Figure 53qczfq is an exploded view of a variant of the cold tail connection means of Figure 53qczfo.

Figure 53qczfr is an exploded view of another variant of the cold tail connection means of Figure 53qczfo.

Figure 53qczg is a schematic cross-section view along X-X of Figures 53qczf and 53qczfo.

Figure 53qczh is a schematic view of the chassis of Figures 53qcz, 53qczb and 53qcze and a heating element plate and heat transfer plate prior to engagement

Figure 53qczi is a schematic view of the chassis of Figures 53qcz, 53qczb and

53qcze and the heating element plate and heat transfer plate at the first phase of engagement.

Figure 53qczj is a schematic view of the chassis of Figures 53qcz, 53qczb and 53qcze and the heating element plate and heat transfer plate at the second phase of engagement.

Figure 53qczk is a schematic partial section view illustrating the control of Figures 53qcy to 53qczb disengaged with the socket.

Figure 53qczl is a schematic partial section view illustrating the control of Figures 53qcy to 53qczb engaged with a socket. Figure 53qczm is a perspective rear view of the control of Figures 53qcy to 53qczb.

Figure 53qczn is a perspective section view along X-X of Figure 53qczm.

Figure 53qczo is a schematic cross-section view along X-X of Figure 53qczm.

Figure 53qczp is a side view of the control of Figures 53qcy to 53qczb in an off position, in which the user actuator is directly mounted to the trip lever.

Figure 53qczq is a side view of the control of Figures 53qcy to 53qczb in an on position, in which the user actuator is directly mounted to the trip lever.

Figure 53qczr is a side view of the control of Figures 53qcy to 53qczb in an off position, in which the user actuator is pivotally mounted on to the body of the control and is connected to the trip lever.

Figure 53qczs is a side view of the control of Figures 53qcy to 53qczb in an on position, in which the user actuator is pivotally mounted on to the body of the control and is connected to the trip lever.

Figure 53qczu is a schematic view from below of the socket moulding of Figure 53qczb, with electrical conductors in-situ.

Figure 53qczv is a schematic view from below of the socket moulding of Figure 53qczb, showing drainage features.

Figure 53qczw is a perspective top view of the socket moulding of Figures 53qczu and 53qczv, showing drainage features.

Figure 53qczx is a schematic isometric section view of a power base with the socket moulding of Figures 53qczu to 53qczw, showing drainage features of the socket moulding interfacing with drainage features on the power base.

Figure 53qczy is a schematic section view of the power base with the socket moulding of Figures 53qczu to 53qczw, showing drainage features of the socket moulding interfacing with drainage features on the power base.

Figure 53qczz is a schematic view from below of a variant of the socket moulding of Figure 53qczu, with electrical conductors in-situ.

Figure 53qczza is a schematic view from below of the socket moulding of Figure 53qczz, showing drainage features.

Figure 53qczzb is an exploded perspective view of the socket moulding of Figure

53qczz with a lower cordless base.

Figure 53qczzc is a sectional view through Line X-X of Figure 53qczzb.

Figure 53qczzd is an assembled sectional view of the socket moulding and lower cordless base of Figure 53qczzc. Figure 53qczze is an assembled sectional view of the cordless base of Figure 53qczzd with a cover.

Figure 53qczzf is a plan view of the lower cordless base of Figures 53qczzb to 53qczze.

Figure 53qczzg is a plan of the lower cordless base of Figure 53qczzf with a small diameter sized power cable.

Figure 53qczzh is a plan of the lower cordless base of Figure 53qczzf with a medium diameter sized power cable.

Figure 53qczzi is a plan of the lower cordless base of Figure 53qczzf with a large diameter sized power cable.

Figure 53qczzj is an exploded view of an embodiment of the cordless power base of Figure 53qczze

Figure 53qczzk is a schematic cross-section view of an embodiment of the cordless power base of Figure 53qczzj engaging with the control of Figure 53qczg. Detailed Description of the Embodiments

[0022] The following description discloses innovations that individually, or in combination, will impact upon very specific appliance designs and may also find use in alternative domestic and commercial appliances.

[0023] The embodiments are presented in separate sections of this document and each of these sections will include a brief introduction to the specific problem.

[0024] To avoid duplication of the background, the description refers to lowering prices, reducing material costs and reducing size etc. but in doing so is taking into consideration each of the above aspects that may be relevant to the specific disclosure. [0025] Within the statement of invention, description and claims, unless otherwise stated, the upward and downward directions refer to the orientation of a vessel when placed upright on a horizontal surface. Axial refers to the principal, normally substantially vertical axis of the vessel. Radial refers to a direction substantially orthogonal to the axial direction, but does not necessarily imply that the vessel is circular cylindrical.

[0026] Within the statement of invention, description and claims, unless otherwise stated, any female connector or connecting part that includes the live electrical parts will be hereon referred to in the description as the socket and any male connector or connecting part that plugs into the socket will be hereon referred to as the plug. [0027] In the following description, functionally similar parts carry the same reference numerals between different embodiments. The drawings are intended to be schematic, and dimensions and angles may not be determined accurately from them unless otherwise stated.

[0028] The following description discloses a combination of measures that will advantageously impact on costs and price in all their aspects.

[0029] At least some embodiments may rely on, or refer to, or relate to, the features of Figure 1 by reference to the reference numerals in Figure 1.

[0030] In the following description the electrical power supply lead into the base 2 or appliance 1 may be described by the term cord (13) and the term cable (336). It is intended that each term has a similar or equivalent meaning.

[0031] Within the statement of invention, description and claims, unless otherwise stated, the terms liquid and water are intended to have equivalent meaning.

[0032] Within the statement of invention, description and claims, unless otherwise stated, the terms kettle, appliance, vessel and reservoir may have equivalent meaning

[0033] Within the statement of invention, description and claims, unless otherwise stated, the terms part and portion are intended to have equivalent meaning.

[0034] Within the statement of invention, description and claims, unless otherwise stated, when describing electrical connections the terms discrete contact, contact portion and contact area are intended to have equivalent meaning.

[0035] Within the statement of invention, description and claims, unless otherwise stated, when describing one part of a heating element the terms heat transfer plate and heat diffuser plate are intended to have equivalent meaning.

[0036] Within the statement of invention, description and claims, unless otherwise stated, when describing one part of a vessel body the terms opening and aperture are intended to have equivalent meaning.

[0037] Within the statement of invention, description and claims, unless otherwise stated, when describing the trip lever and/or control the terms over centre and bistable are intended to have equivalent meaning.

[0038] Figure 1 illustrates schematically a jug kettle with a mechanical actuator, as an example of a liquid heating appliance to which embodiments of the invention may be applied. In this example, the kettle is a cordless kettle comprising a vessel body 1 and a power base 2 having respective body and base cordless connectors 3 and 4, such as 360° cordless connectors of the type described in the applicant's own patent publication WO94/06285 and/or as sold by Otter Controls Ltd under, for example, the CS4/CS7 Series (power base socket) and the Al, CP7 or CP8 (appliance plug) references. The power base 2 is connectable by a power cord 13 to an electrical power outlet (not shown). Each of the vessel 1 and/or base 2 and/or cordless connector 3 and/or cordless connector 4 may be provided with emitters and/or detectors 31, annular seals 21 which may be optically transmissive and/or annular optically transmissive rings 41.

[0039] The jug kettle may include an electro mechanical control 60, for example the applicant's own Al series integrated 360° control, or an electronic control 15. The electro mechanical control 60 may include an integral steam switch 73 or alternatively a discrete steam switch 73a may be provided, within, for example, the handle 9. The appliance may be provided with a switch actuator 305 or 305a which interacts with the control 60, for example through a known over-centre trip lever mechanism (not shown in Figure 1), to toggle between operating states of the appliance. Alternatively an electronic control 15 may employ an alternative user interface 11. Either or both of the electronic control 15 and/or user interface 11 may be situated in one or both of the vessel 1 and/or base 2.

[0040] The vessel body 1 comprises a reservoir 5 for containing liquid to be heated, lid 8, spout 7, handle 9 and a base section 6 having a sub-base portion 19, which forms the bottom surface of the vessel body 1. The spout may provide primary venting and/or pressure equalisation. The lid 8 may be operable to open and close with a user actuator and may be secured to the vessel with a hinge, latch or other means. The lid may be securably sealed to the vessel so that the lid remains in place and does not leak liquid in the case that the appliance is tipped over.

[0041] A steam tube 70 and steam cap 101 may be provided. The steam tube communicates from the area above the water level 225 to the steam switch 73 or 73a. The steam tube may be formed, for example as part of the handle 9 or reservoir wall 5 or as illustrated as a separate tube. In the case that the steam tube passes through the element then a suitable seal 584 and additional steam guide 599 may be provided. The vessel body 1 may be any shape and formed, for example, from plastic, metal, glass or ceramic. The vessel body may comprise a single wall as illustrated or alternatively a twin wall so that, for example, the vessel may be better insulated against heat loss or to render the wall cool to the touch.

[0042] Liquid is heated by an element plate 12 which may form the base of the reservoir 5. The reservoir 5 of the appliance 1 may be provided with water level markings and/or other features that indicate the state of the appliance 1. The element plate 12 includes a heating means and is connected to receive electrical power via the connector 3. The heating means may comprise a sheathed element 39 as illustrated or may comprise a thick film element, induction element and/or diecast element arrangement. There may be provided a heat transfer means 410 and the plate 12 may be composed of stainless steel and/or other suitable substrate. As illustrated the element plate 12 may be sealed into the vessel body 1 using the Easifix (RTM) sealing arrangement as described in WO-A-99/17645 or alternative sealing means may be employed, for example gluing, welding or clamping. The element plate 12 may be supported in the vessel 1 by a removable annular support 401. The element sealing system may also include an intermediate flange 438 between the element plate 12 and the vessel 1.

[0043] At least some embodiments of the present invention are applicable to liquid heating vessels having a heating element immersed in the water, rather than an element on the underside of the vessel.

[0044] At least some embodiments of the present invention are applicable to liquid heating vessels connectable directly by a power cord rather than a cordless connector.

[0045] At least some of the embodiments in the invention are applicable to kettles or heated vacuum flasks and pots, blenders, irons, wasserkochers, coffee and espresso makers, juicers, smoothie makers, food processors, soup makers, sauce makers, steamers, tea makers, chocolate fountains, fondues, slow cookers, vacuum pots, milk frothers, water coolers, water dispensers, pans, vending machine, and/or hot water on demand appliances. It will be appreciated that the above list is not exhaustive.

Reduced Material Integrated Control

[0046] The following description describes embodiments of reduced material integrated controls and associated appliance and appliance components that provide improvement s) over the prior art.

[0047] The following embodiments may include features as described or disclosed with reference to the applicant's patent publication GB-A-2484571. Unless otherwise stated, it is not intended to further describe those features.

[0048] It is the intention of the applicant to seek cost savings in all aspects of an appliance and, given the escalation of labour costs in the traditionally low cost manufacturing areas, consider new methods to simplify the assembly of the control 520 and associated appliance 1.

[0049] Figure 53qca is an isometric view of an embodiment of the control 520 and element plate 12. [0050] The control 520 is based around a 360° cordless plug 3. The control 520 may rely upon the prior art configuration of two separate dry boil actuators which may be bimetal actuators 577, or thermal fuses or a combination of each as described later..

[0051] As shown in Figure 53qca, the control 520 comprises a main moulding 535, a central live pin 530, a hollow earth ring 127 and at least one intermediate sleeve 531 to act as a spacer and insulator between the live pin 530 and the hollow earth ring 127 with a neutral ring 534N spaced apart and around the central pin assembly. Each of the fixed contacts 127, 530 and 534N may include a lateral part 539 (not shown) that acts to position, and assists in securing, the fixed contacts 127, 530 and 534N within the main moulding 535 and may form means to attach a prior art connection means, for example, sheathed or unsheathed conductors (not shown). The distal end of the lateral part 539 (not shown) may include for example a male tab terminal connection 532 (not shown) or female tab terminal and/or resilient springs (not shown). Each of the three fixed contacts 534N, 530 and 127 may be stamped, folded and formed from a flat material such as brass and/or copper alloy and may be plated and/or provided with low resistivity material such as silver

[0052] As shown in Figure 53qca, the control 520 may also include a bimetal actuator 592, supported by a member 593, to control the liquid temperature of the appliance 1. The outer moulding 536 of the plug 3 of the control 520 may form the interface with the socket 4 of the appliance base 2.

[0053] The trip lever 594 may be bistable with the bistable forces being provided by a C spring 811 and may pivot about a point 579 which may be located, for example, on the member 593 or as later described . The trip lever 594 and arm 596 may have at least one arm 596, 870 respectively that interacts with at least one resilient spring contact 137 of the switching means of the control 520. The trip lever 594 may also include bosses 595 or other means for interacting with the user actuator 305. As disclosed in the proprietor's patent application WO-A1-2012/085602, in further embodiments, the trip lever 594 may be vertical to the element plate 12.

[0054] The control 520 may include female bosses 282 or other features 434 for the attachment of additional components, for example the appliance sub base 19 thereto.

[0055] As illustrated the control 520 may be electrically connected to the cold tails 40 of the sheath 39 by a wire conductor 512 by known securing methods for example as described in GB-A-2484571, however a tab terminal 507 or other connection means for example flat and/or folded conductors 512a (as later described) may be provided instead of or in addition to the wire conductor 512. [0056] In further embodiments, for example, at least one cold tail 40 may be adapted, bent or folded vertically away from the element plate 12 so that the wire conductors 512, or other connecting means, may come into contact and interface horizontally with the vertical part of the cold tail 40 in a transverse or complementary arrangement.

[0057] Advantageously, the wire conductors 512 or other connecting means may be provided with horizontal and/or vertical resilience so that wire conductors 512 or other connecting means may resile against one or both of the horizontal or vertical portions of the cold tail 40 so that the position of the weld may be controlled.

[0058] The connection of the wire conductors 512 to the cold tails 40 may then be performed as described in GB-A-2484571or alternatively may be performed in a horizontal action around the vertical part of the cold tails.

[0059] The heat transfer plate 587 may have a cut-out area below the area of the cold tails 40 to provide additional space for the welding process and additional electrical clearance beneath the cold tails 40.

[0060] When viewed from the underside (with the element sheath 39 uppermost), the plane of the element plate 12 beneath the cold tails may be vertically higher than the side face(s) of the element 12c and or 12d so that welding electrodes (not shown) may have horizontal access to the underside of the cold tails.

[0061] As described in GB-A-2484571 a portion of one or both of the wire conductors 512 may be planished to provide a contact plate 518 to act as one part of the switch mechanism within the control 520 and may be supported on a boss 591 provided as part of the control 520. Additional supports 591 and fixtures 517 may be provided so that the wire conductors 512 are firmly fixed within the control 520.

[0062] Alternatively, a resilient portion may be formed from one end of at least one wire conductor 512 so that it may act as one part of the switch means within the control 520. Additionally or alternatively, the resilient wire conductors 512, or other means, may act as switching means in combination with the cold tails 40.

[0063] Figure 53qcb illustrates a detail of Figure 53qca, and Figure 53qcc illustrates the detail of the wire conductor 512 of Figure 53qcb electrically connected to a contact spring 137 in a different perspective view.

[0064] In this embodiment, the wire 512 is supported and secured by a series of supports 517, 591 formed as part of moulding 536 of the integrated control 520. The support 591 may also provide support and securing means for wire conductor 512 of Figure 53qcc. The support 591 may include a boss for example 117 in Figure 53qch which may interface with the aperture 414 in the spring contact 137 to further secure the spring contact 137 to the integrated control 520. The boss 117 may be used to clamp or secure the spring contact 137 to the support 591 by, for example, a hot stake method or other clamping means. Additional portions 792 may be provided in the spring contact 137 for slotting into recesses (not shown) in the support 591. The wire 512 may then be secured to the proximal end of the contact spring 137 by welding 513 or other securing means to ensure electrical conductivity and integrity between the two components 512, 137. The position of the weld 513 or other securing means is hidden from view and it is preferred, but not limiting, that the wire conductor is connected to the spring contact 137 as part of the production assembly of the control 520 or at least prior to the control 520 being assembled to the element plate 12.

[0065] As described with reference to Figure 53qcc, the proximal end of the spring contact 137 may be provided with, for example, a male tab terminal 507 or other connecting means, formed from the spring contact 137 to provide means to make connections for auxiliary components (not shown), for example, lighting or alternatively to connect to the cold tail 40 via for example wires (not shown) instead of the wire conductor 512. In the embodiments as illustrated the distal end of at least one spring contact 137 acts as a switching means with a conductor 530 or 534 of the control 520. In further embodiments the spring contact 137 may form a switch means in conjunction with the wire conductor 512 in which case the distal end of the spring contact 137 may be formed from or directly connected to a conductor 530 or 534 of the control 520 as later described.

[0066] Figures 53qcd and 53qce illustrate a further embodiment in which the shroud 521 of the control 520 is provided with a Molex™ socket 757. The wire 512 may be supported by the supports 517, 591 and connected to the spring contact 137 as described herein. However, in this embodiment the wire 512 is provided with a planished portion 518 which is then located within the lower end of the Molex™ socket 757.

[0067] The Molex™ socket 757 allows a Molex™ connector (not shown) to be connected thereto to provide electricity or power auxiliary components (not shown). Whilst the embodiment shown in Figure 53qcd illustrates the Molex™ socket 757 provided on the male moulding 536, other suitable sockets may be used, for example, a pin socket or header socket, etc.

[0068] As illustrated, the planished portion 518 is at one end of the wire conductor 512, however in other embodiments the planished portion 518 may be positioned at any suitable position along the length of the wire conductor 512. [0069] As in the previous embodiment the terminal point of the contact spring 137 may also be provided with a male tab terminal 507, as illustrated in Figure 53qca, for allowing a female connector (not shown) to be connected thereto.

[0070] Figure 53qcf illustrates a further arrangement for connecting auxiliary components (not shown) to the wire 512, in which a receptacle 528 is provided with a sheath portion 790 and the wire conductor 512 is provided with a corresponding planished portion 518a for engaging with the sheathed portion 790.

[0071] As illustrated in Figure 53qcf the wire conductor 512 has an outer diameter AA, which is less than the inner diameter AB of the sheathed portion 790 of the receptacle 528 and so allows the sheathed portion 790 to pass over the distal end of the wire conductor 512. The enlarged section of the planished portion 518a is similar to, or greater than, the inner diameter AB of the sheathed portion 790 and so provides an interference fit between the two components 518a, 790 when the receptacle 528 is forced over the portion 518a. In doing so the sheathed portion 790 becomes connectively engaged with the planished portion 518a and the receptacle 528 may then be employed to make electrical connections to auxiliary components (not shown).

[0072] Figure 53qcg illustrates a perspective view of a further embodiment whereby the contact spring 137 is provided with a resiliently formed aperture 791 to make electrical connection with the wire conductor 512. The resiliently formed aperture 791 has sufficient resilience to ensure a good electrical connection but may allow the wire 512 to be pivotally or rotatably connected to the contact spring 137 so that the wire 512 can be rotated, as illustrated. This rotation may allow the wire conductors 512 to be rotated after assembly so that the wires 512 may be positioned more within the footprint of the control 520 and so minimize or reduce the footprint of the control 520 and wire 512 during packaging, thus reducing shipping and transport costs. The rotation may further assist in the positioning of the wire 512 against the element cold tail 40 prior to connection.

[0073] In each of the previous embodiments and, for example, as illustrated in Figures 53qca and 53qcd, it is preferred, although not limiting, that the wire conductor 512 is formed along one plane or axis. This arrangement may then allow the same configuration of wire conductor 512 to be used on both sides of the integrated control 520 thus reducing the logistics, tooling and inventory cost of having to provide two separate configurations of wire conductors 512.

[0074] In the case that rework is required in an embodiment that uses a wire conductor 512 that is, for example, welded onto the cold tail 40, then the wire conductors 512 may be cut between the control 520 and the cold tail 40 and then an additional wire conductor 512 can be welded onto the shortened wire conductor 512 of the control 520 prior to reassembly.

[0075] The integrated control 520 comprises two sub-assemblies: the connector assembly 676 and the chassis assembly 675.

[0076] In the prior art, the earth conductor may be formed from an annular ring permanently attached to the chassis through the connector assembly and it is not possible to disconnect the connector assembly 676 from the chassis assembly 675 after the control 520 has been attached to an element plate 12.

[0077] This can present problems for the appliance manufacturer for example:

1) The chassis has to be removably fixed to the element plate in order to enable rework if for example an end of line test shows up a problem with the assembly.

2) The removable fixture means, for example nuts, bolts or screws may be more expensive and take more time to assemble than permanent fixtures such as rivets.

3) The chassis assembly cannot be pre-assembled to the element plate.

[0078] The following embodiments disclose means to overcome the above problems by removably fixing the connector assembly 676 to the chassis assembly 675 so that it is possible to disconnect the connector assembly 676 from the chassis assembly 675 after the control 520 has been attached to an element plate 12.

[0079] Figure 53qch illustrates an isometric view of the integrated control 520 of Figure 53qca from above when not mounted on an element plate 12.

[0080] The connector assembly 676 houses the electrical connecting parts 530, 534, 137 and switching parts 137, 512 of the control 520 and electrically isolates the live and neutral conductors for example parts 530 and 534 from each other and from earth 127. The connector assembly 676 may also include at least one push rod 212 that interacts with the spring contact 137, and a corresponding bimetal 577 on the chassis 590, so that the electrical supply to the appliance 1 may be interrupted if the bimetal 577 senses an overheat or dry boil condition. In further embodiments the push rod 212 may form or interact with a thermal fuse (not shown) or other thermal actuator means.

[0081] As described and illustrated with reference to Figure 53qch, the spring contact 137 may be housed within the shroud 521 and supported by the support 591. The spring contact 137 may be provided with an aperture 414 for receiving a boss 117 to enable the spring contact 137 to be located and further secure the spring contact 137 to the integrated control 520. The boss 117 may be used to clamp or secure the spring contact 137 to the support 591 by, for example, a hot stake method or other clamping means. [0082] The proximal end of the spring contact 137 may be provided with a male contact tab or terminal 507 to provide power to auxiliary components or alternatively or additionally may be connected to a wire conductor 512.

[0100] The connector assembly 676 may also include steam bimetal 592 and a trip lever 594 with bosses 595 that may interact with at least one switch means (not shown) in the control 520 to interrupt the power to the appliance 1 in the case that, for example, the appliance contents have reached a pre determined temperature.

[0101] The chassis assembly 590 may include mounting means 573 for at least one bimetal 577, which means 573 may also act to stabilize the chassis assembly 675 against the element plate 12 when assembled.

[0102] At least two feet or supports 574 may be formed with apertures 570 for attaching the chassis 590 to the element plate 12 and further supports 569 and 559 may also be provided for datum and stability.

[0103] At least one tab 424 may be stamped or punched out from the material of the chassis 590 to act as a means to attach or clamp the connector assembly 676 to the chassis assembly 675.

[0104] The tab(s) 424 may be twist tab(s) and may be used to attach the chassis 590 to the connector assembly 676 as described in the proprietors' granted patent GB2342685B.

[0105] Alternatively the tab(s) may be foldable during assembly so that each tab acts as a clamping means to secure the connector assembly 676 onto the chassis assembly 675.

[0106] At least one male tab 507 may also be stamped or punched out from the material of the chassis 590 and utilised as a terminal to provide a removable connection means between the earth conductor 127 and the chassis 590 as later described.

[0107] The chassis 590 may also be provided with a strengthening rib 558.

[0108] The chassis may be manufactured from stainless steel, mild steel or plated steel for example zinc or aluminium plated steel.

[0109] Figures 53qci to 53qcn illustrate and describe the engagement means and stages thereof between the connector assembly 676 and the chassis assembly 675 and in particular the connection of the earth ring 127 to the chassis 590.

[0110] Figures 53qcj and 53qck illustrate exploded isometric views of the chassis 590 and the earth ring 127 from above and below respectively and Figure 53qco details the earth ring in the same perspective view as Figure 53qcj. For clarity and illustrative purposes all other components are removed from the figures. [0111] The earth ring 127 is provided with a resilient spring clip 552 at its upper end for engaging a contact tab 507 provided on the chassis 590 and the spring clip 552 is provided with at least one tapered location feature 759.

[0112] As illustrated in Figures 53qcj and 53qck the earth ring 127 may be formed from a sheet material and the substantially annular portion of the earth ring 127 may maintain its rigidity without the need for additional strengthening means.

[0113] In other embodiments, as illustrated Figure 53qco, to lower costs the material thickness of the earth ring 127 may be reduced such that additional strengthening means may be required, for example, a mechanical interlocking finger joint 758 may be provided on the substantially annular portion of the earth ring 127 to increase its rigidity. In further embodiments other interlocking joints, for example, dovetail joints may be used.

[0114] The inner diameter of the earth ring 127 is aligned with a central aperture 414 provided on the chassis 590 and the spring clip 552 of the earth ring 127 is aligned with the contact tab 507 on the chassis 590.

[0115] Figure 53qci illustrates a cross sectional view through line X-X of Figure 53qch in which the chassis assembly 675 and the connector assembly 676 are in a fully assembled state.

[0116] As illustrated the earth ring 127 may be insulated from the central conductor 530 by an insulating sleeve 531 which may be formed from, for example, a plastic or ceramic material. This same insulator 531 may add additional rigidity to the earth ring and provide further opportunities to reduce the material thickness and reduce the material costs.

[0117] At the same time at least one tab 424 is aligned to engage with the corresponding moulding 536 of the integrated control 520. After engagement, the tab(s) 424 may be twisted or folded so that the chassis 590 is secured to the male moulding 536.

[0118] Figures 53qcl to 53qcn illustrates the engagement phases of the assembly of the chassis assembly 675 with the connector assembly 676.

[0119] As illustrated in Figure 53qcl and described above, the inner diameter of the earth ring 127 is aligned with an aperture 414 and the spring clip 552 is aligned with the contact tab 507. The insulating sleeve 531 of the cordless connector is provided with a boss 117 which also aligns with the aperture 414 in the chassis 590.

[0120] The distal end of the spring clip 552 is provided with at least one tapered location feature 759. During the first phase of engagement, as illustrated in Figure 53qcm, the tab 507 is located within and engages the tapered location feature 759. [0121] During the second phase of engagement, as illustrated in Figure 53qcn, the tab 507 forces the tapered location feature 759 to open to allow the tab 507 to engage the spring clip 552, while the boss 117 engages with the aperture 414 in the chassis 590.

[0122] During the first and second phases at least one tab 424 is aligned to engage with the corresponding moulding 536 of the integrated control 520.

[0123] In the final stage the tab 507 fully engages with the spring clip 552 and earth continuity is achieved. After engagement, the tab(s) 424 may be twisted or folded so that the chassis assembly 675 is fully secured to the connector assembly 676.

[0124] Advantageously the tabs 424 are accessible after the control 520 has been assembled to an element so that connector assembly 676 may be removed from chassis assembly 675 if required, for example for rework.

[0125] In controls 520 including bimetals 577 that act as safety means, it is very important that the bimetals are in close contact with the element plate 12 so that the bimetals 577 may react quickly in abnormal conditions; for example, if the water heating appliance is energized when empty.

[0126] In the prior art there is little or no resilience in the chassis 590 in which case the assembly is reliant upon a flat element plate 12 to ensure that the interface of the bimetal 577 and the element plate 12 is within tolerance.

[0127] In the prior art at least three fixing or clamping means 574, 755, 756 (screws, nuts bolts etc.) are utilised to ensure that the chassis 590 is fully secured on the plate.

[0128] Generally these fixing points are positioned at a distance from the bimetal area to avoid interfering with, for example, the flatness in the area of the bimetal.

[0129] Generally there is little or no resilience in the chassis 590 in which case the assembly is reliant upon the flatness of the element plate 12 between the fixture means 755 to ensure that the interface of the bimetal 577 and the plate 12 is within tolerance.

[0130] Generally a heat sink paste, for example Dow Corning 340, is positioned between the bimetal 577 and the element plate 12 to counteract any tolerance issues between the bimetal 577 and the element plate 12 and so improve the heat transfer from the element plate 12 towards the bimetal 577. The heat sink paste is expensive and difficult to apply and it would be preferable if this process could be eliminated.

[0131] The following embodiments disclose an improved resilient chassis 590 in which the chassis 590 is resiliently supported in the proximity of the bimetal and the height of this support is dependant upon the plane of the element plate 12 in the area of the bimetal and therefore more tolerant to an uneven element plate surface. [0132] Furthermore the following embodiments only require two fixture means 755 which significantly reduces the assembly time and costs.

[0133] Figure 53qcp illustrates an isometric view of the chassis 590. The chassis is provided with at least three datum points that act to support and position the chassis assembly 675 during and after assembly. Two supports 569 in the proximity of the bimetal 577 (shown in dotted lines) provide the first two datum points and at least one further support 559 positioned opposite to the first two supports 569 provide at least a third datum point.

[0134] As illustrated the supports 559,569 provide an initial triangulation point of contact between the chassis 590 and the heating element plate 12 which will be further described below.

[0135] The supports 569 may be formed from a resilient chassis arm 568 and may also include back stops 598 which may provide an accurately controlled datum point for the dry boil blade 577 when the chassis 590 is fully mounted on the heating element plate 12.

[0136] The chassis 590 is provided with two dry boil blade mounts 573, in which the central portion of each dry boil blade 577 (shown in dotted lines) is mounted thereto.

[0137] The chassis 590 is also provided with two mounting flanges 574 to allow the chassis 590 to be secured to the element plate 12 via, for example, the mounting studs 755 and nuts 756, which will be described in more detail below.

[0138] Figures 53qcq to 53qct schematically illustrate four stages in the mounting of the resilient chassis 590 against the element plate 12. For clarity and illustrative purposes, nonessential components are removed from the figure. The positions and dimensions of the features in the figures are for illustrative purposes only and should not be limiting on the scope of the invention.

[0139] Figure 53qcq illustrates the mounting flanges 574 aligned with the mounting studs 755 in the first stage of assembly.

[0140] Figure 53qcv illustrates the second stage of the assembly. In order to provide a secure fixing for the resilient chassis 590 the inboard mounting points 574 and 573 are on marginally different planes to the outboard support means 569 and 559. in this way, when the chassis 590 is presented to the plate 12 the outboard support means 569, 559 are in contact with, and form an initial triangulation point with, the plate 12 and the inboard mounts 574 and 573 are marginally apart (Gap A and Gap B) from the plate 12. Furthermore the Gap A between fixture 574 and the plate 12 is greater than the Gap B between the fixture 573 and the plate 12. [0141] Figure 53qcs illustrates the third stage of the assembly, in which the nut 756 (or other clamping means) is initially tightened during which the outboard support means 569, 559 remains in contact with the element plate 12. As such the resilient chassis arm 568 flexes under compression and the dry boil blade mount 573 is urged into contact with the element plate 12 whilst gap B has been reduced in depth.

[0142] Figure 53qct illustrates the fourth stage of the assembly in which the nut 756 (or other clamping means) is fully tightened so that the chassis mount 574 is fully secured against the element plate 12 so that the whole chassis 590 is under compression.

[0143] In addition, as described previously, the chassis 590 may be provided with a rib 558 for strengthening and to prevent deformation thereof, in particular when the chassis 590 is under compression and is fully engaged with the element plate 12.

[0144] Advantageously the chassis 590 is fully secured against the element plate 12 using two clamping means only and the blade mount 573 and support 569 are each in close contact with the element plate 12 in the area of the bimetal 577.

[0145] The centre portion of the dry boil blade is mounted in blade mount 573 and the rear portion of each dry boil blade 577 is located within a corresponding back stop 598 within the support 569. The back stop 598 acts a fulcrum point for the bimetal 577 when actuated so that the front portion of the dry boil blade 577 may act against the push rod 212. The push rod 212 would then disconnect the power/electricity being supplied to the spring contact 137 and pushes the trip lever 594 to the off position.

[0146] Controlling the height of the back stop as part of the resilient arm 568 provides further assurance that relationship between the bimetal 577, element plate 12 and pushrod 212 are optimised and helps ensure that the control 520 is more capable of working consistently across a broad range of element tolerances

[0147] Advantageously the close control of the dimensions in the region of the bimetal may provide the opportunity to reduce or eliminate the application of heat sink compound between the bimetal 577 and the plate 12.

[0148] Upon disassembly the nuts 756 or other clamping means are removed, the chassis arm 568 may return to its original position and be reused.

[0149] Advantageously the previously described tabs 424 are accessible after the control 520 has been assembled to an element so that connector assembly 676 may be removed from chassis assembly 675 if required, for example, for rework. In this case, the clamping means 755, 756 may be provided by a less expensive non reworkable solution, for example, a rivet formed from the heat transfer plate 587. [0150] In further embodiments (not shown) the chassis 590 or selected parts of the chassis 590 may be provided as part of the element plate 12 and so provide further opportunities to reduce the material costs and assembly time of the control 520 into the appliance 1.

[0151] Another method of reducing appliance assembly costs is to reduce or eliminate the fixtures required to attach the sub base 19 to the control 520 and the sub base 19 to the reservoir 5.

[0152] Figures 53qcu to 53qcx illustrate a series of embodiments that enable the elimination of the aforementioned fixtures whilst still complying with the industry standard requirements for the sub base 19 to be 'tamper free'. This is the requirement that the sub base 19 should not be removable without the use of specialist tools which are not normally available to a consumer or householder, for example, security screws (tamper proof) that require a non standard screw driver to disassemble.

[0153] Figure 53qcu illustrates an exploded isometric section view of the integrated control 520 mounted on the heating element plate 12 along with the associated sub base 19 in which integrated control 520 may be provided with a series of retaining means, for example barbs 434 on the periphery of the connector 3, for engaging with corresponding snap fits 425 provided on the sub base 19.

[0154] As illustrated in Figure 53qcv an aperture 414 may be provided in the proximity of each snap fit 425 to allow access to the snap fit 425 and/or barb 434 for disengaging in order, for example, for reworking.

[0155] The aperture 414 may be adapted to allow the manufacturer and/or approved repairer to remove the sub base 19 to gain access to internal components, whilst preventing the end user from access if using conventional tools. For example, the aperture 414 may have a key hole configuration (not shown) that prevents a standard screwdriver accessing the sub base or the retaining means may have a specific form that would require a special tool to disengage the retaining means.

[0156] Figure 53qcw illustrates an alternative embodiment to Figure 53qcv, whereby the sub base 19 is provided with spring clips 552 with hook arrangements 734 that may be insert moulded into the sub base 19 or alternatively secured within slots 690 provided in the sub base.

[0157] The spring clips 552 may then engage with a series of retaining means 434 in a snap fit manner or alternatively a tool (not shown) may be used to retract the spring clips 552 with the hook arrangement 69 land then release the hook 691 when the spring clip has passed the barb 434. [0158] As described herein, the aperture 414 may be provided in the proximity of each spring clip 552 to allow access for engaging the spring clips 552 with the hook 691 or for disengaging the same components.

[0159] Additionally, the aperture 414 may function as a draining hole for the appliance.

[0160] By using snap fittings as opposed to security screws for securing the sub base to the control 520, the cost of the appliance may be reduced by reducing the number of components.

[0161] Figure 53qcx is a detailed view illustrating an embodiment where the sub base 19 is secured to the appliance body by a series of snap fits 403 provided on the sub base 19 for mutually engaging with slots 405 provided on the internal wall of the appliance body 1. Each snap fit 403 is provided with a corresponding hook 734. An aperture 414 may be provided in the proximity of each snap fit 403 to allow access to the hook 734 to disengage the snap fits 403 in the case it is necessary to disassemble the sub base 19 from the appliance 1.

[0162] The central portion of the sub base 19 is provided with a skirt 559 that abuts the male moulding 536 of the integrated control 520 to prevent upward movement of the sub base 19 and may be provided with one or more securing means 434,552, 425 as described above to further secure the sub base onto the control 520.

[0163] The skirt 559 may also function as a weir or barrier to prevent water or condensate from exiting the appliance via the connector 3. The bottom wall of the sub base 19 is substantially concave to direct water towards the peripheral wall of the sub base 19 and drain out of the appliance via the apertures 414.

[0164] Additionally, the sub base 19 comprises a substantially annular peripheral wall that forms a substantially annular support rib 401 which may support the element seal 400 which may in turn act to support the element plate 12 for example using the applicant's Easifix® sealing system.

[0165] As described above the sub base 19 may be provided with apertures 414 for disengaging the sub base from the appliance.

[0166] The embodiments shown in Figures 53qcu to 53qcx eliminate the requirement for additional mechanical fixtures thus reducing the material costs and assembly costs.

[0167] The embodiments illustrated in Figures 53qa to 53qcx disclose a series of embodiments and methods for reducing the overall cost of an appliance including an integrated control 520, whilst improving the opportunity for rework and the resulting further cost savings. [0168] Figures 53qcy to 53qczs describe a further embodiment of reduced material integrated controls embodiments and associated appliance and appliance components.

[0169] Figure 53qcy is an isometric view of a further embodiment of the control 520 and element plate 12.

[0170] The control 520 is similar in function as the previously described control but includes improvements including, but not limited to the 360° cordless plug 3, the chassis 590, electrical connection means 127, 530, steam switch actuator 592 and steam inlet 860. The control 520 may rely upon the prior art configuration of two separate dry boil actuators which may be bimetal actuators 577, or thermal fuses (not shown), or a combination of each.

[0171] As shown in Figure 53qcy, the control 520 comprises a main moulding 535, a central live pin 530, a neutral ring 534N and an earth ring 127. Each of the fixed contacts 127, 530 and 534N may include a lateral part 539 (not shown) that acts to position, and assists in securing the fixed contacts 127, 530 and 534N within the main moulding 535 and may form means to attach a prior art connection means, for example, sheathed or un-sheathed conductors (not shown). The distal end of the lateral part 539 (not shown) may include for example a male tab terminal connection 532 (not shown) or female tab terminal and/or resilient springs (not shown). Each of the three fixed contacts 534N, 530 and 127 may be stamped, folded and formed from a flat material such as brass and/or copper alloy and may be plated and/or provided with low resistivity material such as silver.

[0172] As shown in Figure 53qcy, the control 520 may also include a bimetal actuator 592, supported by a member 593, to control the liquid temperature of the appliance 1. The outer moulding 536 of the plug 3 of the control 520 may form the interface with the socket 4 of the appliance base 2.

[0173] The trip lever 594 may be bistable with the bistable forces being provided by a C Spring 811 and may pivot about a point 579 which may be located on the member 593. The trip lever 594 may have at least one arm 596 that interacts with at least one resilient spring contact 137 of the switching means of the control 520. The trip lever 594 and arm 596 may also include bosses 595, 870 respectively or other means for interacting with the user actuator 305.

[0174] The control 520 may include female bosses 282 or other features 434 for the attachment of additional components, for example the appliance sub base 19 thereto.

[0175] As illustrated the control 520 may be electrically connected to the cold tails 40 of the sheath 39 by known securing means for example a wire conductor 512 as described in GB-A-2484571, however a tab terminal 507 (not shown) or other connection means may be provided instead of or addition to the wire conductor 512.

[0176] In further embodiments, for example, at least one cold tail 40 may be adapted, bent or folded vertically away from the element plate 12 so that the wire conductors 512, or other connecting means, may come into contact and interface horizontally with the vertical part of the cold tail 40 in a transverse or complementary arrangement.

[0177] Advantageously, the wire conductors 512 or other connecting means may be provided with horizontal and/or vertical resilience so that wire conductors 512 or other connecting means may resile against one or both of the horizontal or vertical portions of the cold tail 40 so that the position of the weld may be controlled.

[0178] The connection of the wire conductors 512 to the cold tails 40 may then be performed as described in GB-A-2484571 or alternatively may be performed in a horizontal action around the vertical part of the cold tails.

[0179] The heat transfer plate 587 may have a cut-out area below the area of the cold tails 40 to provide additional space for the welding process and additional electrical clearance beneath the cold tails 40.

[0180] When viewed from the underside (with the element sheath 39 uppermost), the plane of the element plate 12 beneath the cold tails 40 may be vertically higher than the side face(s) of the element 12c and or 12d so that welding electrodes (not shown) may have horizontal access to the underside of the cold tails 40.

[0181] As described in GB-A-2484571, a portion of one or both of the wire conductors 512 may be planished to provide a contact plate 518 (not shown) to act as one part of the switch mechanism within the control 520 and may be supported on a boss 591 provided as part of the control 520. Additional supports 591 and fixtures 517 may be provided so that the wire conductors 512 are firmly fixed within the control 520.

[0182] Alternatively, a resilient portion may be formed from one end of at least one wire conductor 512 so that it may act as one part of the switch means within the control 520. Additionally or alternatively, the resilient wire conductors 512, or other means, may act as switching means in combination with the cold tails 40.

[0183] In the embodiment of Figure 53qcy, the wire 512 is supported and secured by a series of supports 517, 591 formed as part of moulding 536 of the integrated control 520. The support 591 may also provide support and securing means for wire conductor 512 of Figure 53qcc. The support 591 may include a boss for example 117 (as shown in Figure 53qcz) which may interface with the spring contact 137 to further secure the spring contact 137 to the integrated control 520. The boss 117 may be used to clamp or secure the spring contact 137 to the support 591 by, for example, a hot stake method or other clamping means. Additional portions 792 may be provided in the spring contact 137 for slotting into recesses (not shown) in the support 591. The wire 512 may then be secured to the proximal end of the contact spring 137 by welding 513 or other securing means to ensure electrical conductivity and integrity between the two components 512, 137. The position of the weld 513 or other securing means is hidden from view and it is preferred, but not limiting, that the wire conductor is connected to the spring contact 137 as part of the production assembly of the control 520 or at least prior to the control 520 being assembled to the element plate 12.

[0184] As previously described with reference to Figure 53qcc, the proximal end of the spring contact 137 may be provided with, for example, a male tab terminal 507 (not shown) or other connecting means, formed from the spring contact 137 to provide means to make connections for auxiliary components (not shown), for example, lighting or alternatively to connect to the cold tail 40 via for example wires (not shown) instead of the wire conductor 512. In the variant as illustrated and referenced herein, the distal end of at least one spring contact 137 acts as a switching means with a conductor 530 or 534 of the control 520. In further variants the spring contact 137 may form a switch means in conjunction with the wire conductor 512 in which case the distal end of the spring contact 137 may be formed from or directly connected to a conductor 530 or 534 of the control 520.

[0185] In a further variant, the shroud 521 of the control 520 may be provided with a Molex™ socket (not shown) for wire conductor of Figure 53qce. The wire 512 may be supported by the supports 517, 591 and connected to the spring contact 137 as described herein. However, in this variant the wire 512 is provided with a planished portion 518 which is then located within the lower end of the Molex™ socket 757.

[0186] The Molex™ socket (not shown) allows a Molex™ connector (not shown) to be connected thereto to provide electricity or power auxiliary components (not shown). Alternatively, the male moulding 536 of the control 520 may be provided with, other suitable sockets, for example, a pin socket or header socket, etc.

[0187] As illustrated in Figure 53qce, the planished portion 518 is at one end of the wire conductor 512, however in other variants the planished portion 518 may be positioned at any suitable position along the length of the wire conductor 512. [0188] As in the previous variant the terminal point of the contact spring 137 may also be provided with a male tab terminal 507, as illustrated in Figure 53qca, for allowing a female connector (not shown) to be connected thereto.

[0189] Figure 53qcf illustrates a further variant for connecting auxiliary components (not shown) to the wire 512, in which a receptacle 528 is provided with a sheath portion 790 and the wire conductor 512 is provided with a corresponding planished portion 518a for engaging with the sheathed portion 790.

[0190] As illustrated in Figure 53qcf the wire conductor 512 has an outer diameter AA, which is less than the inner diameter AB of the sheathed portion 790 of the receptacle 528 and so allows the sheathed portion 790 to pass over the distal end of the wire conductor 512. The enlarged section of the planished portion 518a is similar to, or greater than, the inner diameter AB of the sheathed portion 790 and so provides an interference fit between the two components 518a, 790 when the receptacle 528 is forced over the portion 518a. In doing so the sheathed portion 790 becomes connectively engaged with the planished portion 518a and the receptacle 528 may then be employed to make electrical connections to auxiliary components (not shown).

[0191] Figure 53qcg illustrates a perspective view of a further variant of the resilient spring whereby the contact spring 137 is provided with a resiliently formed aperture 791 to make electrical connection with the wire conductor 512. The resiliently formed aperture 791 has sufficient resilience to ensure a good electrical connection but may allow the wire 512 to be pivotally or rotatably connected to the contact spring 137 so that the wire 512 can be rotated, as illustrated. This rotation may allow the wire conductors 512 to be rotated after assembly so that the wires 512 may be positioned more within the footprint of the control 520 and so minimize or reduce the footprint of the control 520 and wire 512 during packaging, thus reducing shipping and transport costs. The rotation may further assist in the positioning of the wire 512 against the element cold tail 40 prior to connection.

[0192] In the present embodiment, as illustrated in Figure 53qcy, it is preferred, although not limiting, that the wire conductor 512 is formed along one plane or axis. This arrangement may then allow the same configuration of wire conductor 512 to be used on both sides of the integrated control 520 thus reducing the logistics, tooling and inventory cost of having to provide two separate configurations of wire conductors 512.

[0193] In the case that rework is required in an embodiment that uses a wire conductor then the wire conductors may be cut between the control 520 and the cold tail 40 and then an additional wire conductor 512 can be welded onto the shortened wire conductor 512 of the control 520 prior to reassembly.

[0194] Figure 53qcz illustrates an isometric view of the integrated control 520 of Figure 53qcy, from above, when not mounted on an element plate 12.

[0195] The connector assembly 676 houses the electrical connecting parts 530, 534N, 127 and switching parts 137, 512 of the control 520 and electrically isolates the live and neutral conductors for example parts 530 and 534 from each other and from earth 127. The connector assembly 676 may also include at least one push rod 212 that interacts with the spring contact 137, and a corresponding bimetal 577 on the chassis 590, so that the electrical supply to the appliance 1 may be interrupted if the bimetal 577 senses an overheat or dry boil condition. In further embodiments the push rod 212 may form or interact with a thermal fuse (not shown) or other thermal actuator means.

[0196] As described and illustrated with reference to Figure 53qcz, the spring contact 137 may be housed within the shroud 521 and supported by the support 591. The shroud 521 may be provided with bosses 117 to enable the spring contact 137 to be located and further secure the spring contact 137 to the integrated control 520. Alternatively, the spring contact may be provided with an aperture 414 (not shown) for receiving a boss 117 to enable the spring contact 137 to be located and further secured to the integrated control 520. The boss 117 may be used to clamp or secure the spring contact 137 to the support 591 by, for example, a hot stake method or other clamping means.

[0197] The proximal end of the spring contact 137 may be provided with a male contact tab or terminal 507 (not shown) to provide power to auxiliary components or alternatively or additionally may be connected to a wire conductor 512.

[0198] The connector assembly 676 may also include steam bimetal 592 and a trip lever 594 with bosses 595 that may interact with at least one switch means (not shown) in the control 520 to interrupt the power to the appliance 1 in the case that, for example, the appliance contents have reached a pre-determined temperature.

[0199] The chassis assembly 590 may include mounting means 573 for at least one bimetal 577, which said mounting means 573 may also act to stabilize the chassis assembly 675 against the element plate 12 when assembled.

[0200] At least two feet or supports 574 may be formed with apertures 570 for attaching the chassis 590 to the element plate 12 and further support(s) 559 may also be provided for datum and stability. [0201] At least one tab 424 may be stamped or punched out from the material of the chassis 590 to act as a means to attach or clamp the connector assembly 676 to the chassis assembly 675.

[0202] The tab(s) 424 may be twist tab(s) and may be used to attach the chassis 590 to the connector assembly 676 as described in the proprietors' granted patent GB-B-2342685.

[0203] Alternatively the tab(s) 424 may be foldable during assembly so that each tab acts as a clamping means to secure connector assembly 676 to the chassis assembly 675.

[0204] As illustrated in Figure 53qcz, the connector assembly 676 and the chassis assembly 675 may be further secured together with a screw 288 or other suitable fastening means, for example, riveting, hot staking, clamps or snap fitting etc. The screw 288 may be used for controlling the deflection and deformation between the connector assembly 676 and the chassis assembly 675 during manufacturing, assembling and operation.

[0205] At least one male tab 507 may also be stamped or punched out from the material of the chassis 590 and utilised as a terminal to provide a removable connection means between the earth conductor 127 and the chassis 590 as later described.

[0206] The chassis 590 may also be provided with a strengthening rib 558.

[0207] The chassis 590 may be manufactured from stainless steel, mild steel or plated steel for example zinc or aluminium plated steel.

[0208] Supports 574 may include vertical portions 856 which may be provided with an aperture 555 to reduce the thermal path and or heat conduction between the element plate 12 (not shown) and the connector assembly 676, such that heat from the element plate 12 (not shown) does not adversely affect the main moulding 535 of the connector assembly 676.

[0209] Figure 53qcza illustrates an isometric view of the integrated control 520 of Figure 53qcy from below.

[0210] The connector assembly 676 houses the electrical connecting parts 530, 534N, 127 in a concentric arrangement. The bimetal actuator 592 is supported by a member 593, to control the liquid temperature of the appliance 1. The member 593 also functions as a steam inlet 860, which will be described in more detail below.

[0211] Figure 53qczb illustrates an exploded view of the integrated control 520 of Figures 53qcy to 53qcza.

[0212] The appliance control 520 comprises the main moulding 535, and at least three conductors the central live pin 530, the neutral ring 534N and the earth ring 127. Each of the conductors 534N, 530 and 127 may include a lateral part 539 that acts to position, and assists in securing, the conductors 534N, 530 and 127 within the main moulding 535 and form means to provide the Live, Neutral and Earth connections for the appliance The distal end of the lateral part 539 may include terminal connection 532 or may act as fixed contact plates501. Each of the conductors 534E, 530 and 127 may be stamped, folded and formed from a flat material such as brass and/or copper alloy and may be plated with a low resistivity material such as silver.

[0213] The lateral parts 539 may be post formed or folded after being inserted through the apertures 545 (not shown) in the top part of the main moulding 535 or may be separate parts attached to the conductors 127, 530 and 534N during the assembly. At least one of the lateral parts 539 may be positioned on the underside of the top part of the moulding 535 in which case just the terminal part 532, 501 may pass through the top part of the main moulding 535.

[0214] In the case that the connector 3 needs to be waterproof then the cavity 526 (not shown) formed by the wall 522 (not shown) may be also be filled with an insulating sealant, for example, silicone as described by example in the application patent publication GB-A- 2440411.

[0215] In further variants, the sealant may alternatively and/or additionally be applied from the underside of the moulding 535.

[0216] In further variants the conductors 127, 530 and 534N, lateral parts 539 and/or connections 532, 501 may be insert moulded as part of the main moulding 535.

[0217] The base connector 4 comprises a main moulding 536 in which two annular apertures 541 and 542 and a central aperture 564 are formed by the walls 546, 547 and 868 and may include shrouds 560 on the underside to provide electrical insulation and/or water shedding for the aforementioned electrical connection means, for example, tab terminals 532. The assembly also includes three moving contacts 137E (earth), 137L (live) and 137N (neutral) which interface with the respective conductors 127, 530 and 534N when the appliance connector 3 is inserted into the base connector 4.

[0218] As illustrated, the main moulding 536 of the connector 4 may comprise an annular lip 853, in which an annular well 882 may be formed between the wall 547 and the annular lip 853. The annular well 882 may function as a drainage feature, which will be described in more detail below.

[0219] A wall 567 may be provided in the main moulding 536 to form a collective drainage port 567a, for at least two of the annular well 882 and/or the annular apertures 541 and 542, for draining water safely away from the connector 4, and details of which will be described in more detail below. [0220] As illustrated the moving parts are resilient springs which may be manufactured from beryllium copper or more preferably from a beryllium free material, for example, Olin (ref C7025) and may include low resistance contact portions 544 (not shown). In further embodiments the resilience for the moving contact parts may be provided by other means or additional parts, for example, coiled springs.

[0221] The resilient springs 137E, 137L and 137N include lateral parts 539 with fixtures 533 for assembly into the main moulding 536 and connection means 532. The resilient spring 137E is positioned within the outer channelled aperture 542 and the resilient spring 137N within the inner channelled aperture 541 and the resilient spring 137L within the central aperture 564.

[0222] Figures 53qczc and 53qczd illustrate variants of the live pin 530 of Figures 53qcy to 53qczb for electrically connecting from the resilient spring 137L of the socket 4 to the live spring 137L (not shown) of the control 520.

[0223] It is known that the fixture of discrete low resistivity contacts 509 onto the distal ends of a solid pin is a problematic and expensive process, in particular, the assembling of the location and fixture means.

[0224] As shown in Figure 53qczc, the live pin 530 may comprise a solid conductor secured to a contact plate 501L by for example a rivet 515. Alternatively, other suitable securing methods may be used, for example, splaying and screwing etc. The central conductor and contact plate 501L may be formed for example from brass and/or copper alloy. In the case that this solid pin type is used for applications where the control 520 experiences low arcing current and/or low wattage then there may be no need to either plate and/or provide contact 509 at the distal end.

[0225] As shown in Figure 53qczd, an alternative live pin 530 may be stamped and/or folded and/or formed from a flat material such as brass and/or copper alloy. As illustrated, the live pin 530 may comprise a hollow central portion 857 with a contact plate 501L extending therefrom for electrically connecting to live spring 137L (not shown) of the control 520.

[0226] Prior to folding the hollow pin 530, a discrete silver contact 509 may be, for example, welded onto the material so that it subsequently forms the contact between the pin 509 and the resilient spring 137L of the socket 4. The contact 509 may be provided or fed from a continuous length and cropped after welding. The low conductivity material fits partly or substantially within the post formed hollow portion. Advantageously, this provides both lower material and manufacturing costs compared with the prior art method of fixing a discrete contact 509 onto the distal end of a solid pin.

[0227] For clarity purposes, Figure 53qczd illustrates a partial section view through the live pin 530 to show the position of the contact 509.

[0228] In an alternative embodiment the hollow portion 857 may be, for example, swaged over at the distal end to provide a contact area and this contact area may be plated with a low resistivity material for example silver.

[0229] It will be appreciated that the live pin of Figure 53qczc and Figure 53qczd are interchangeable depending upon the specific loading requirements of the intended application. The live pin 530 of Figure 53qczd including the discrete low resistivity contact 509 may be suited for applications where the control 520 experiences high arcing current and high wattage, and the lower cost live pin 530 of Figure 53qczc may be suitable for applications where the control 520 experiences low arcing current and low wattage and hence provide a lower cost version of the control 520.

[0230] Figure 53qcze shows an exploded isometric view of the chassis 590, female connector moulding 535 and the earth ring 127 from below in order to illustrate the electrical connection of the earth ring 127 onto the chassis 599 and the fixture of the earth ring 127 onto the main moulding 535. For clarity and illustrative purposes, all other components are removed from the figure.

[0231] The earth ring 127 is provided with a resilient spring clip 552 at its distal end for engaging a contact tab 507 provided on the chassis 590 and the spring clip 552 is provided with at least one tapered location feature 759.

[0232] As illustrated in Figure 53qcze the earth ring 127 may be formed from a sheet material and the substantially annular portion of the earth ring 127 may maintain its rigidity without the need for additional strengthening means.

[0233] In other embodiments, to lower costs the material thickness of the earth ring 127 may be reduced such that additional strengthening means may be required, for example, a mechanical interlocking finger joint may be provided on the substantially annular portion of the earth ring 127 to increase its rigidity. In further embodiments other interlocking joints, for example, dovetail joints may be used.

[0234] The inner diameter of the earth ring 127 is aligned with a central aperture 414 provided on the chassis 590 and the spring clip 552 of the earth ring 127 is aligned with the contact tab 507 on the chassis 590. [0235] The earth ring 127 may be provided with tabs 424 that may be inserted through the apertures 545 (not shown) in the top part of the main moulding 535. The tabs 424 would be folded to secure the earth ring 127 to the main moulding 535 during the assembly process.

[0236] It is known to provide at least one dry boil blade or thermal fuse as a safety feature to prevent overheating of the heating element. In overheating conditions, the dry boil blade would disconnect power from the control. One of the problems with using a thermal bimetal blade as a safety dry boil mechanism is that the deflection of the thermal bimetal blade may need to be converted to a linear motion to interface with the switching means in order to disconnect the switching means of the control. The embodiment below describes a separate push rod guide 850 for guiding movement of the push rod such that the deflection of the thermal bimetal blade is converted to a linear motion for disconnecting the switching means of the control. Advantageously, the push rod guide may also act as insulation between the chassis 590 and the electrical parts and as a clamping means for at least one contact plate 501L and 501N.

[0237] Figure 53qczf illustrates the integrated control 520 of Figure 53qcz, with the chassis 590 removed for clarity and illustrative purposes. Figure 53qczfa schematically illustrates the bimetal blade 577 mounted on the chassis 590. Figure 53qczg illustrates a schematic cross section along X-X of Figure 53qczf.

[0238] The centre portion of the dry boil blade is mounted in blade mount 573 and the rear portion of each dry boil blade 577 resiles or rests against a corresponding back stop 598 on the chassis 590. The back stop 598 acts a fulcrum point for the bimetal 577 when actuated so that the front portion of the dry boil blade 577 may act against the push rod 212. A push rod guide 850 is provided for guiding movement of the push rod 212 such that the deflection of the thermal bimetal blade is 577 converted to a linear motion for disconnecting the switching means of the control 520.

[0239] The push rod(s) 212 would then push against the resilient spring contacts, for example, 137L and 137N and so disconnect the said resilient springs from the contact plates 501L and 50 IN. This action also provides the impetus to force the trip lever 594 through the bistable mechanism and into the Off position.

[0240] The push rod guide 850 is provided with bosses 855 for clamping the contact plate 501L, 50 IN to the moulding 535 and as described above acts as an electrical insulation means between the chassis 590 and electrical part of the control 520. [0241] The push rod guide 850 may also be provided with walls 854 which in conjunction with the main moulding 535 may provide a shroud around the switching means, for example, to prevent debris or other foreign matter entering this critical area.

[0242] Figures 53qczfb, 53qczfc, 53qczfd and 53qczfe illustrate a further embodiment of the control 676 which comprises improvements and/or alternatives over the previous embodiment of Figure 53qca. It is only intended to further describe the improvements and/or alternatives and for clarity Figures 53qczfb, 53qczfc, 53qczfd and 53qczfe are illustrated in similar views to Figures 53qcz, 53qcza, 53qczf and 53qczfa.

[0243] Figure 53qczfb is an isometric illustration of the control assembly 676 (in the same view as Figure 53qcz) in which there is provided an extended resilient spring 137 that may also act as the conductor 512. The resilient spring 137 may be secured to the control assembly 676 in the area of the shroud 521 by, for example, a boss 117. The resilient spring conductor 137/512 will be described in further detail later.

[0244] Figure 53qczfc is an isometric illustration of the control assembly 676 (in the same view as Figure 53qcza) in which there is provided at least one pocket 757 that may provide access and support for additional electrical connection means, for example a Molex ® connector, that may cooperate with, for example, the resilient spring conductor 137/512.

[0245] Figure 53qczfd is an isometric illustration of the control assembly 676 (in the same view as Figure 53qczf). Figure 53qczfd illustrates the control assembly 676 with the chassis 590 removed so that the push rod guide 850 is visible. The push rod guide 850, which is illustrated in detail in Figure 53qczff, may include at least one additional wall 854a to further prevent debris or other foreign matter entering the critical electrical contact area. The additional walls 854a may include small diameter apertures 819 so that, for example, probes may be inserted for production line testing and/or audit.

[0246] Figure 53qczfe is an isometric illustration of the chassis 590 (in the same view as Figure 53qczf) which illustrates the additional tabs 415 of the chassis 590 which may be secured around, for example, the main moulding 535 of the control assembly 676. The chassis 590 may also include the previously described securing means, for example, the twist tabs 424.

[0247] Figure 53qczfg is an isometric illustration of a resilient spring conductor 137/512 that may combine the portion 137 that may act as a resilient spring contact of the switching means of the control 520 and the portion 512 that may act as a connecting means to, for example, the cold tails 40 of the heating element 39. The spring 137/512 may include a low resistance contact 544 for the switching means; an aperture or clench feature 511 for securing the spring 137/512 against the previously described boss 117 of the control assembly 676; a folded portion 507 that may as further securing means or may act as a contact portion, for example, for the previously described Molex ® connectors; and may include at least one profiled portion 572a for the correct positioning of the conductor 512 in relationship with the cold tails 40. The shape and/or form of the resilient spring conductor 137/512 may be, for example, stamped out of strip material, or as later described, may be formed from a continuous strip of material.

[0248] In the prior art it is known to fixably secure connectors such as male or female tab terminals or receptacles onto the distal ends of one or both of the conductors 517 and/or cold tails 40 for electrical connection of the two components. However, there are known problems with the securing of such connectors for example overheating in the area of the connection and/or mismatch of the male and female connections. Furthermore in order to ensure the connectors are electrically conductive it is necessary to use electrically conductive material such as brass or tin plated brass, however these materials are expensive and add to the cost of the assembly.

[0249] It is also known, as previously described, to weld the conductors 517 onto the cold tails 40 however, as previously described, it is not always possible to gain access for the welder and/or there may be rework issues if, for example, the conductor 512 cannot be easily removed from the cold tail 40.

[0250] It is also known to bias the conductor 512 against the cold tail 40 but again there may be overheating issues if the contact pressure of the electrical connection is compromised by for example damage to the conductor 512 prior to or during assembly.

[0251] The embodiment of Figure 53qczfh and 53qczfi put forward an alternative arrangement to the prior art methods, in which a resilient clip 552 may be provided in order to mechanically and/or electrically secure the conductor 512 against the cold tail 40. The clip 552 comprises flat material folded into, for example, a resilient R shaped form with, for example, a fold 552a at one end forming biasing means. One side (illustrated as the underside) of the clip 552e may be substantially flat and the other side (illustrated as the top side) may include a downward facing portion 552b, a profiled portion 552c and an upwardly angled portion 552d at its distal end that may form an opening 552f in the clip 552 to assist in assembly. The opening 552f may be further enhanced by the provision of a downward facing portion (not shown) at the distal end of the portion 552e.

[0252] In use, the opening 552f of the resilient clip 552 is pushed over the conductor 512 and transverse cold tail 40 so that the flat portion 552d clamps against the length of the conductor 512 and the profiled portion 552c clamps across and around the cold tail 40. The conductor 512 may be resiliently biased against the cold tail 40 prior to assembly and may include at least two positional features 572a, 572b in order to restrict and/or limit lateral movement of the clip 552, relative to the conductor 512, during and after assembly. The feature 572a may be provided from material that protrudes outwardly from the width of the conductor 512 as illustrated in Figure 53qczfh and/or the feature 572b may be provided from material within the width of the conductor 512, for example as illustrated in Figure 53qczfj . Alternatively, at least one of the features 572 may take the form of pips and/or indents raised out of or through the conductor 512.

[0253] The profiled portion 552c of the clip 552 may act to further anchor/secure the clip 552 to the cold tail 40 and restrict and/or limit forward or backward movement of the assembled clip 552 and in alternative embodiments at least one portion of the clip 552 may comprise positional features 572 to cooperate with the conductor 512 in order to restrict and/or limit lateral movement.

[0254] The distance G, between the inside top surface of the profiled portion 552c and the top surface of bottom portion 552e, must be less than the diameter of the cold tail 40 so that when assembled the biasing means of the clip 552 applies a constant contact pressure between the mating conductor 512 and transverse cold tail 40.

[0255] It is known that the capability of the manufacturing process in attaching the element sheath 39 to the plate 12 may result in a relatively wide positional deviation, from element to element, of the cold tail 40 relative to the element plate 12. The conductor 512 of the control 676 will be indexed relative to the element plate 12 in which case it may be necessary for the conductor 512 and/or the clip 552 to provide compliance in order to accommodate the aforesaid positional variation.

[0256] As indicated in Figure 53qczfh the positional deviation may include:

i) The angular deviation of the cold tail 40 (angle X) which may be in any orientation relative to the centre line of the cold tail 40 for example between the cold tail 40 and the element plate 12 and/or between the cold tail 40 and the conductor 12.

ii) The height A between the cold tail 40 and the element plate 12a

iii) The distance H between the centre line of cold tail 40 above the conductor 512 and the outer perimeter of the plate 12 -

For clarity the Figure 53qczfh is based on a nominal position in which the cold tails 40 are substantially in line with each other and substantially parallel to the plate 40 and the cold tails 40 and conductor cross at 90°, however this is not limiting to the invention. [0257] The clip 552 and conductor 512 may be configured to provide compliance against the deviation of angle X between the cold tail 40 and the conductor 512 whilst still providing the means to secure the clip to the conductor 512.

[0258] In the embodiment of Figure 53qczfh, for example, the strip width Dimension F, of at least the portion 552e of the clip 552 may be less than the Dimension C between the features 572 of the conductor 512 so that the clip 552 may be fitted diagonally between the features 572 to provide compliance whilst the portion 552c fits substantially parallel to the cold tail 40. In further embodiments the features 572 may be provided on the clip 552 in which case the width of the conductor 512 in the area of the clip 552 may be less than the distance between the features 572 on the clip 552 and so provide a similar angular compliance.

[0259] Similarly Dimension E across the widest part of the internal surface of the profile of 552c, may be wider than the diameter of the cold tail 40 so that the cold tail 40 may fit marginally diagonally within the profile 552 and so provide angular compliance between the clip 552 and the cold tail 40.

[0260] The clip 552 and the conductor 512 may be also be configured to provide radial compliance against distance H between the cold tail 40 and the outer perimeter of the plate 12. The radial deviation may be measured between the centre line of cold tail 40 and the end of the conductor 512 (Dimension B) and may be defined to be the total of the minimum overlap required between the cold tail 40 and the end of the conductor 512 and the maximum angular and radial deviation of the cold tails 40 about the centre line relative to the perimeter of the plate 12.

[0261] In which case, in the embodiment of Figure 53qczfh, the distance D between the centre of the profile 552c and the internal surface of the folded portion 552a must be greater than Dimension B so that when the clip 552 is assembled, the folded portion 552a does not bottom against the end of the conductor 512 prior to the cold tail 40 fully engaging the profiled portion 552c of the clip 552.

[0262] In alternative embodiments each of the conductors 512 and/or clip 552 may be provided with, for example, a centrally located indent or feature 572 and the corresponding clip 552 and/or conductor 512 may be provided with a slot so that the clip 552 may rotate and slide along the slot and so provide each of the previously defined angular and radial compliance. [0263] It is expected that the rotational resilience of the flat conductor 512 may provide the required compliance against the angular deviation X and the height deviation A between the cold tail 40 and the element 12.

[0264] In further embodiments, not shown, clips 552 may be used in conjunction with other forms of conductors 512 including the previously described wire conductors.

[0265] As illustrated the clips 552 cooperate with conductors 512 positioned between the cold tails 40 and the element plate 12, but are equally applicable to embodiments where the cold tails 40 are positioned between the conductors 512 and element plate 12.

[0266] In the case that the clip 552 is made from a low resistance material then the clip 552 may act as an additional conductor between cold tail 40 and conductor 512 and may allow the use of lower resistance materials for the conductor 512 and/or cold tail 40 and so reduce the costs of these components.

Advantageously, in the case that the clip 552 is not intended to be conductive, then the clip 552 may be manufactured from lower cost, less conductive material for example mild steel.

[0267] It is known in the prior art to stamp out a plurality of complex parts including an angled or shaped form, for example conductors 137/512, from flat material, which may be in the form of a strip. The complex parts are nested together to mitigate waste, however it is not always possible to nest the parts in such a manner that precludes all waste and in particular, for example, between the individual, stamped parts and/or between the stamped parts and the edge or indexing portion of material.

[0268] Figures 53qczfk to Figure 53qczfn illustrate further embodiments whereby the conductor 512 of Figure 53qczfg may be formed from a continuous strip of material of the required width and the shaped portions may be formed from folding the strip material. Advantageously, it is possible to sequentially crop the continuous strip material to the required length of each conductor 512a so that none of the strip material is wasted.

[0269] Figure 53qczfk illustrates the conductor 512a prior to folding in which there may be provided a contact 544 and aperture and or clench feature 511 which may later act as an indexing means.

[0270] The conductor 512a may then be folded so that portions of the conductor 512a, 512b and 512c may change direction in horizontal and vertical planes as illustrated in Figure 53qczfl and/or the conductor 512a may change direction in a substantially horizontal plane only as illustrated in Figure 53qczfm and Figure 53qczfn. The conductor 512a may include a plurality of folds of different angles as required and the folds may be stamped or pressed in such a manner that the fold may plastically deform the conductor material in the area of the fold so that the fold substantially stays in place. Conductor material not subjected to the forces of the fold, for example a distal end, may still retain a degree of resilience.

[0271] Figure 53qczfm illustrates an example of a strip conductor 512a after folding, in comparison with a stamped conductor 512 in situ and it can be seen that two obtuse angle folds may create a similar shaped conductor 512a to the stamped conductor 512.

[0272] For strip conductors 512a that require a broader platform for example to support a contact 544 or a connection 888 to a cold tail 40 (as later described), then a wider portion can be configured, for example, by folding the portions 512b, 512c and 512d, as illustrated in Figure 53qczfn. As illustrated the wider portion may be formed on at least one end of the conductor 512 however the same folding principle may be used to form a wider portion in any position across the length of the conductor 512.

[0273] Figure 53qczfo to Figure 53qczfr illustrate embodiments of the previously described stamped and/or folded conductor 512, that may be electrically connected to a cold tail 40 by a interference fit assembly method that accommodates the previously described deviation of the cold tail in relation to the element plate 12. The following embodiments may be described and illustrated with reference to the conductor 512, however the embodiments are equally applicable to the other conductors including but limited to the folded conductors 512a.

[0274] In the first embodiment as illustrated in Figures 53qczfo and 53qczfp, in unassembled and assembled state respectively, the distal end of the conductor 512 may be provided with fixture means 888 comprising a central aperture 888a and a plurality of apertures 888b radiating away from the central aperture 888a so a series of resilient barbs 888c may be formed. The portion 888 may be folded and/or twisted perpendicular to the plane of the conductor 512 so that the aperture 888a may be in line with the cold tail 40. The end portion 888 may be formed from a series of folded portions for example 512b, 512c, and 512d as previously described. During assembly the portion 888 is forced over the cold tail 40 and the barbs 888c may distort, acting to form an electrical and mechanical connection with the cold tail 40. The cold tail 40 may be provided with a least one retention means, for example, an indent or protrusion, not shown, to engage with at least one resilient barb 888c to retain the conductor 512 onto the cold tail 40 after the assembly. The conductor 512 may be provided with a series of folds 887 that may act to expand and contract under force to provide longitudinal compliance for aligning the aperture 888a with the cold tail 40 across the range of manufacturing tolerances. [0275] Figure 53qczfq illustrates a second embodiment, whereby the distal end of the conductor 512 may be provided with fixture means 888 comprising at least one horizontal aperture 888d and may further comprise at least one vertical apertures 888g so that at least one elongate barb 888e may be formed on at least one side of the horizontal aperture 888d. During assembly the portion 888 is forced over the cold tail 40 and the barb(s) 888e may distort, acting to form an electrical and mechanical connection with the cold tail 40. The horizontal aperture 888d may provide longitudinal compliance for aligning the aperture 888a with the cold tail 40 across the range of manufacturing tolerances, in which case there may be no requirement for the series of folds (as illustrated in Figure 53qczfo) to provide the longitudinal compliance.

[0276] Figure 53qczfr illustrates a third embodiment, whereby the distal end of the conductor 512 may be provided with the previously described horizontal aperture 888d further comprising a series of, for example, vertical apertures 888g which may form a series of vertical barbs 888f projecting towards the horizontal aperture 888d. During assembly the portion 888 is forced over the cold tail 40 and only the required portion of the bards 888f may distort, acting to form an electrical and mechanical connection with the cold tail 40. As described previously, the horizontal aperture 888d provides longitudinal compliance for aligning the aperture 888a with the cold tail 40 across the range of manufacturing tolerances.

[0277] As previously described each of the cold tails 40 may be provided with at least one retention means, for example, an indent or protrusion, not shown, to engage with at least one resilient barb 888e, 888f to retain the conductor 512 onto the cold tail 40 after the assembly.

[0278] As illustrated in Figure 53qczg, connection means for example variants of 532L, 532N may be provided at any suitable positions along the length of the conductor 137/512 to provide means to make connections for auxiliary components (not shown), for example, lighting.

[0279] By providing the connection means along the unswitched portion of the conductor 137/512, power to the auxiliary components will not be affected if the trip lever 594 (not shown) is in its Off position.

[0280] The connections means may be provided by discrete connectors for example Molex™ type connectors as previously described or, for example, wires may be welded directly to the contact plates 501L and 50 IN.

[0281] Figures 53qczh to 53qczj schematically illustrate three stages in the mounting of the resilient chassis 590 against the element plate 12. For clarity and illustrative purposes, non- essential components are removed from the figures. The positions and dimensions of the features in the figures are for illustrative purposes only and should not be limiting on the scope of the invention.

[0282] Figure 53qczh illustrates the mounting flanges 574 aligned with the mounting studs 755 in the first stage of assembly.

[0283] Figure 53qczi illustrates the second stage of the assembly. In order to provide a secure fixing for the resilient chassis 590 the inboard mounting points 574 are on a marginally different plane to the outboard support means 559 and the dry boil blade mount 573. In this way, when the chassis 590 is presented to the plate 12 the outboard support means 559 and the dry boil blade mount 573 are in contact with, and form an initial triangulation point with, the plate 12 and the inboard mounts 574 are marginally apart (Gap C) from the plate 12.

[0284] Figure 53qczj illustrates the third stage of the assembly in which the nut 756 (or other clamping means) tightens the inboards mount 574 directly to the element plate 12 and in doing so provide the force to ensure the outboard support means 559 and the dry boil blade mount 573 are held firmly and securely against the element plate 12.

[0285] In addition, as described previously, the chassis 590 may be provided with a rib 558 for strengthening and to prevent deformation thereof, in particular when the chassis 590 is under compression and is fully engaged with the element plate 12.

[0286] Advantageously the chassis 590 is fully secured against the element plate 12 using two clamping means only and the blade mount 573 is in close contact with the element plate

12 in the area of the bimetal 577.

[0287] The centre portion of the dry boil blade is mounted in blade mount 573 and the rear portion of each dry boil blade 577 is rested on a corresponding back stop 598 on the chassis 590. The back stop 598 acts a fulcrum point for the bimetal 577 when actuated so that the front portion of the dry boil blade 577 may act against the push rod 212. The push rod 212 would then disconnect the power/electricity being supplied to the spring contact 137 and pushes the trip lever 594 to the off position.

[0288] Advantageously the close control of the dimensions in the region of the bimetal may provide the opportunity to reduce or eliminate the application of heat sink compound between the bimetal 577 and the plate 12.

[0289] Upon disassembly the nuts 756 or other clamping means are removed, the chassis 590 may return to its original shape for reuse. [0290] In further embodiments (not shown) the chassis 590 or selected parts of the chassis 590 may be provided as part of the element plate 12 and so provide further opportunities to reduce the material costs and assembly time of the control 520 into the appliance 1.

[0291] It is known to provide means to ensure that the kettle does not become energised when replaced on its power base after being emptied. Examples of such means include the applicants granted patents GB-B-2331628 and EP-B-0380416.

[0292] The prior art assemblies normally require multiple components which add cost and complexity.

[0293] The following description describes a further means to provide a simplified arrangement that does not involve multiple components.

[0294] Figure 53qczk and 53qczl illustrate schematic cross sections of the appliance connector 3 for use with previous embodiments of the control 520. The inlet moulding 535 of the appliance connector 3 comprises an annular passageway 858 into which a power base connector 4 may be engaged.

[0295] The moulding 535 of the appliance connector 3 carries a trip-lever 594 mounted in a bistable arrangement which provides pivotal movement of the trip lever 594 between two stable positions. The bistable action may be provided by a "C" spring 811 (not shown).

[0296] The trip lever 594 may pivot about a point 579 which as previously described may be located on the main moulding 535. The trip lever 594 may also include bosses 595 or other means for interacting with the user actuator 305.

[0297] A substantially horizontal resilient cantilevered spring 861 is provided in which its proximal end is secured to the moulding 535 and is biased towards the annular passageway.

[0298] The distal end 869 of the resilient cantilevered spring 861 is formed at substantially 90° to the spring portion and is located though an aperture 859 into the annular passageway 858. The downwardly extending portion 869 is operable to engage with the moulding 536 of the power base connector 4. The downwardly extending portion 869 may include a fold 871 or other feature to prevent damage or snagging when engaging or disengaging with the connector 4. A horizontal portion 872 of the resilient cantilevered spring 861 further interfaces with a boss 862 provided on the trip lever 594.

[0299] Thus, as will be apparent from Figure 53qczk, when the liquid reservoir and the power base are separated, the downwardly extending angled portion 869 in its first position protrudes into the annular passageway, and the horizontal portion of 872 engages with the boss 862 of the trip lever 594 and prevents the bistable trip lever 594 from being switched to an On' position. [0300] When the cordless connector 4 is engaged with the appliance connector 3, the moulding 536 of the connector 4 is urged against the resilient cantilevered spring 861 pushes the spring 861 upwards to its second position so that resilient spring 861 does not come into contact with the trip lever 594 such that the trip lever 594 can operate in either the On' and/or Off position as required.

[0301] In the case that the liquid reservoir is removed from the power base with the appliance connector 3 in its On' position then the resilient cantilevered spring 861 will return to its first position, i.e. the downwardly extending angled portion 869 protruding into the annular passageway, 858 and the resilient cantilevered spring 861 will act against the trip lever 594 to cause the bistable trip lever 594 to move to its Off position, as shown in Figure 53qczk.

[0302] In which case a single resilient component acts in cooperation with the trip lever 594, the control moulding 535 and the power base connector 4 to ensure that the trip lever 594 of the vessel 1 may only be switched on when positioned on the base and will automatically revert to the Off position when removed from the base.

[0303] It is known in the prior art to provide a steam tube that communicates between the upper portion of an appliance reservoir (i.e. the area above the water level, in use) and a steam control provided on the underside of the base of the reservoir.

[0304] With the prior art arrangements, the steam bimetal may not be in the direct flow of the steam path and the speed of response of the steam control may be inhibited.

[0305] The following embodiment describes an integrated means to direct the steam onto the steam bimetal 592 which may provide a quicker steam response without substantially increasing the size and material of the control 520.

[0306] Figures 53qczm and 53qczn illustrate an isometric view and an isometric cross section view of the control 520 of Figures 53qcy to 53qczb. Figure 53qczo illustrates a cross section of the control 520 of Figures 53qcy to 53qczb.

[0307] As illustrated in Figures 53qczn and 53qczo, the control 520 may include a bimetal actuator 592, supported by a member 593, to control the liquid temperature of the appliance 1. The control 520 includes a steam inlet 860 which fluidly communicates with an inclined surface 873 beneath the bimetal 592. The inclined surface directs the steam path 72 towards the bimetal actuator 592 to actuate the trip lever 594, and thus improving the response of the bimetal actuator 592.

[0308] In further embodiments the bottom face 874 of the control 520 may be closed off with a separate component to form a steam channel in cooperation with the inlet 860 or alternatively the appliance sub base 19 may act to close off the face 874 to form the steam channel.

[0309] In alternative embodiments the incline 873 may be formed in the appliance sub base 19 and form that steam channel as previously described.

[0310] Figures 53qczp to 53qczs illustrate two pivotal arrangements (in dotted lines) for or a user actuator 305 (not shown).

[0311] Figures 53qczp and 53qczq illustrate the trip lever 594 in its Off and On' position with the user actuator firmly attached to the trip lever.

[0312] Figures 53qczr and 53qczr illustrate the trip lever 594 in its Off and On' position, in which the user actuator is pivotally mounted on to the body of the control and is connected to the trip lever.

[0313] It can be appreciated that the arcuate movement at the end of the trip lever will increase as the length of the trip lever increases which may be a problem for larger diameter vessels.

[0314] Figure 53qczr illustrates an alternative arrangement, in which the user actuator 305 is connected to a trip lever boss 870 closer to the centre of the appliance than the pivot of the control and then pivots about a fixed boss 551 provided on the main moulding 535 between the trip lever boss 870 and the proximal end of the user actuator. This arrangement effectively reduces the angle at which user actuator pivots between the On' and the 'off positions and therefore reduces Dimension AC at any given length actuator in comparison to the previous arrangement previous arrangement in which case this second arrangements is more suitable for larger diameter appliances.

Improved Water Shedding in 360° Cordless Connectors

[0315] In other prior art 360° connectors (not shown), for example the proprietors CS4 series, it is known to provide a full height moulded skirt as part of base 2 so that the moulded skirt acts to provide the initial engagement between the base 2 and the plug 3. This skirt may alleviate the water ingress issues between the socket 4 and the base 2, however there maybe interface and tolerance issues between the skirt moulded by the appliance manufacture as part of the base 2 and the plug 3 and socket 4 supplied by the component manufacturer.

[0316] It is also known to provide cordless bases without a skirt and care must be taken to accommodate any liquid that may be present where the connector 4 interfaces with power base 2. [0317] It is also known to provide a central drainage within a cordless connector so that any liquid that is present on the top surface of the connector 4 may drain through the connector 4 and then out of the base through cooperating drainage channels.

[0318] The following embodiments may include features as described or disclosed with reference to the applicant's patent publication GB-A-2484571. Unless otherwise stated, it is not intended to further describe those features.

[0319] Figure 53qczu illustrates the cordless connector 4 of Figure 53qzcb from below, in which the three moving contacts 137E (earth), 137L (live) and 137N (neutral) are in- situ. The moulding 536 of the socket 4 may be provided with shrouds 560 with a recess 561 as previously described with reference to the applicant's patent publication GB-A-2484571 to provide electrical insulation and/or water shedding for the aforementioned electrical parts 532. As illustrated in Figure 53qczw, the end of each shroud 560 is provided with an upwardly extending wall 560a to deflect water away from the end and towards the sides of the recess 561.

[0320] Figure 53qczv illustrates the cordless connector 4 of Figure 53qczu, in which the moving contacts are removed for clarity and illustrative purposes. Figure 53qczw illustrates a perspective view of the cordless connector 4 of Figures 53qczu and 53qczv from above.

[0321] The main moulding 536 of the socket 4 may be provided with a central aperture 564 and at least two concentric annular apertures 541 and 542 to allow access for the conductor 530, 534N and 127 of the control 520 to make contact with the respective resilient connectors 137L, 137N and 137E of the connector 4.

[0322] The apertures 541 and 542 and a central aperture 564 may be formed by the walls 546, 547 and 868. The walls 546, 547 and 868 also act to provide electrical insulation between the conductors and also provide insulation to prevent the user touching live parts.

[0323] The central portion 564 may provide drainage means for the central conductor(s).

[0324] The walls 546 and 547 may be provided with vertical apertures 565a and 565b within the collective drainage port 567a to improve the drainage from the two annular apertures 541, 542.

[0325] The cordless connector 4 may also be provided with indexing or location features 883.

[0326] As illustrated in Figure 53qczw, an aperture 346a may be provided in the annular well 882 of the connector 4 to provide drainage from the annular well 882, such that any liquid that enters the well 882 annually or circumferentially, for example between the top surface of the base cover moulding 343 and the connector 4, may be safely drained away as illustrated via the collective drainage port 567a.

[0327] The wall 547 of the connector 4 may be provided with a vertical aperture 565c extending upwardly from the aperture 346a to improve the drainage from the top surface of the cover moulding 343.

[0328] In alternative embodiments, the aperture 346a may be in liquid communication with a separate drainage port (not shown).

[0329] As illustrated in Figure 53qczy, the base cover moulding 343 may include a skirt 871 for engaging with the annular lip 853 of the connector 4 for centralising the connector 4 within the base cover moulding 343 during assembly.

[0330] In further embodiments, an annular lip (not shown) may extend from the top cover moulding and into the well 882 to further improve the drainage from the top surface of the cover moulding 343.

[0331] Each of the areas that provide drainage are marked in hatched lines in Figures 53 qczv and 53 qczw.

[0332] In the illustrated embodiment the central drainage 564 is contained and channelled by a wall 562 and the drainage of 565a, 565b and 565c is contained and channelled by the wall 567. Each of the walls 562 and 567 act as segregated drainage ports to manage the drainage through the connector 4.

In further embodiments each of the apertures, for example, 565a, 565b, 565c may each be segregated by discreet drainage ports.

As illustrated the apertures 565a, 565b, 565c are aligned, and in further embodiments the apertures that may be staggered or offset from/to each other.

[0333] Figures 53qczx and 53qczy illustrates schematic section views of the cordless connector 4 of Figures 53qczb and 53qczu to 53qczw mounted in a power base 2.

[0334] The power base 2 may be provided with at least one shroud 852 for at least mutually engaging with the drainage port 567a of the connector 4. The drainage port 567a is fluidly connected to the drainage apertures 565 of the annular apertures 541, 542 and annular well 882, and the drainage port 562a is fluidly connected to the central aperture 564. The drainage ports 562a, 567a are fluidly connected with at least one aperture 346b on the underside of the power base 2. Therefore, any liquid entering the connector 4 may be segregated and channelled through the underside of the power base 2. [0335] The central portion of the power base 2 may be provided with an annular skirt 851 that function as a weir or barrier to contain any excess liquid or condensate and divert this liquid towards an aperture 346b in the power base 2.

[0336] Figures 53qczz and 53qczza illustrate a further variant to the previously described connector 4 in which there are provided support members 884 that may act to support the plug 4 within the sub base 851 as later described.

[0337] In the embodiment of Figures 53qczz and 53qczza the drainage feature 567 has been rotated (relative to the conductors 532) when compared with the previous embodiments however, unless otherwise stated, the rotational position of the drainage feature 567 is not limiting.

[0338] The following embodiments may include features as described or disclosed with reference to the applicant's patent publication WO-A1-2012/085602 and the previously described embodiments. Unless otherwise stated, it is not intended to further describe those features.

[0339] Figures 53qczzb to 53qczzd illustrate perspective views of the further variant of the cordless connector 4 of Figures 53qczz and 53qczza in combination with a lower power base 2a.

[0340] As previously described, the lower power base 2a may be provided with at least one shroud 852 for at least mutually engaging with the drainage port 567 of the connector 4 to allow the drainage port to be fluidly connected with at least one aperture 346b on the underside of the lower power base 2a.

[0341] The drainage port 567 may be further provided with location means 883, for example a click fit, for mutually engaging with locations means 883a provided on the shroud 852. The location means 883, 883a may further function as alignment means to ensure that the drainage port 567 is aligned with the aperture 346b.

[0342] As previously described, the central portion of the lower power base 2 may be provided with the annular skirt 851 that function as a weir or barrier to contain any excess liquid or condensate and divert this liquid towards an aperture 346b in the lower power base 2a.

[0343] The cordless connector 4 may be provided with a series of support means, for example feet 884 located, on its underside to engage with, for example, abutment features 885 provided on the lower power base 2a. When assembled as illustrated in Figure 53qczzd, the drainage port 567 engages with the shroud 852 and the feet 884 rest on the abutment features 885 so that connector 4 is aligned and/or indexed with, and supported by, the lower power base 2a.

[0344] Figure 53qczze illustrates the connector 4 and lower power base 2a of Figure 53qczzd with the previously described base cover moulding 343. The base cover moulding 343 may be provided with an annular skirt 851a which may overlap the skirt 851 of the lower power base 2a for aligning and/or indexing the base cover 343 with the lower power base 2a. Fixture means (not shown), for example snap-fits, click fits, screws and/or rivets may be provided to secure the base cover 343 to the lower power base 2a.

[0345] As previously described, the vertical aperture 565c of the connector 4 allows water on the top surface of the cover moulding 343 to be drained via the aperture 346b.

[0346] As illustrated in Figure 53qczze, the lower power base 2a may be provided with cable retention features 340, as described and/or disclosed in the applicant's patent publication WO-A1-2012/085602.

[0347] Figures 53qczzf to 53qczzi illustrate plan views of the lower power base 2a configured to fit with different sized power cables 345a, 345b, 345c so that, for example, a single standard moulding is suitable for use across range of cables and the so the single standard moulding may be used across a range of appliances as disclosed in WO-A1- 2012/085602.

[0348] As illustrated in the Figure 53qczzf, the lower power base 2a may comprise a series of walls 359a, 359b, 359c extending from the lower power base 2a to form a central region 360 for receiving the connector (not shown for clarity purposes). As illustrated, cable routes 358a, 358b, 358c may be provided between the annular skirt 851 and the walls 359a, 359b, 359c for receiving different sized power cables 345a, 345b, 345c, which will be described in more detail below. At least one aperture 414a may be provided in the annular skirt 851 to allow the power cable 345 to pass therethrough.

[0349] As illustrated, a series of cable retention features 357a, 357b may be provided in a staggered arrangement between the wall 359a and the annular skirt 851 to create cable routes 358a and 358b to suit different sized power cables 345a, 345b, 345c.

[0350] As illustrated in Figures 53qczzh and 53qczzi, respectively the length of cable retention features 357 may be arranged such that the longer cable retention features 557a are suitable for smaller or medium sized cables 414a and the shorter cable retention features 358b are suitable for receiving larger sized power cables 414b.

It is intended that the cable retentions features 357 cooperate with the outer sheath of the cable 345 only, after which the outer sheath may be removed and individual conductors may then be cut to length and enter the central region 360, via the channel 358 and apertures 414c, as required, to be connected to the connector (not shown).

[0351] Alternatively or additionally at least one cable retention feature 357c, for example in the form of a vertical post, may be provided to act in combination with a corresponding feature, for example 359b, in the wall 359a and the annular skirt 851, to clamp against the cable 345c. The cable retention feature 357c may also include angular features on its outer surface to help secure the cable 345c.

[0352] As illustrated in Figure 53qczzg, at least one vertical post 357 and corresponding feature 359b may be provided in the single base moulding 2a for use with cables 345c, for example, which may be too narrow in at least one plane to be securely clamped by the longest of cable retention features 357a.

[0353] In the case that the cable retention feature 357c is not required then the cable 345 may by-pass the cable retention feature 357c as, for example, illustrated in Figure 53qczzh. [0354] Figure 53qczzj illustrates an embodiment of the cordless power base 2 of Figure 53qczze, whereby the power base 2 is a reduced sized cordless power base as described in the applicant's patent publication WO-Al-2012/085602, which, as disclosed, may be implemented, for example, for reducing the size of packaging.

[0355] The cordless power base 2 may comprise the previously described lower power base 2a and connector 4 with a power base cover moulding 2b. The cordless base assembly may be supplied prewired to a cable as disclosed in for use WO-Al-2012/085602 and be used as a standard assembly across a range of appliances, either as a discrete base assembly 2 (which may be hidden by the appliance 1) or alternatively in combination with a removable base cover 343. The removable base cover 343 may be a single piece moulding, or a plurality of mouldings joined or hinged, for example, as illustrated in Figure 53qczzj .

[0356] An aperture 349 may be provided in the base cover 343 for receiving the cordless power base 2.

[0357] The base cover 343 may comprise cable retention features on its underside as described in the applicant's patent publication WO-Al-2012/085602.

[0358] Figure 53qczzk is a schematic cross-section view of an embodiment of the cordless power base 2 of Figure 53qczzj engaging with the control 60 of Figure 53qczg.

[0359] As illustrated, the connector 4 comprises improvements and/or alternatives over the previous embodiment of Figure 53qczzb, whereby the outer moulding 547 may be removed, which may further reduce the mass or volume of the more expensive engineering type plastics used on the connector 4. The resilient earth conductor 137E may be formed as previously described, protruding upwardly from connector 4 ready to cooperate with the corresponding earth ring 127 on the mating control 676. The resilient earth conductor 137E may be provided within a discrete moulding as indicated by the dotted lines 361 to protect the conductor 137E for example when inserting the appliance on the base.

[0360] In further embodiments a plurality of discrete mouldings 361 may be provided on the same pitch diameter, for example, to provide additional guidance for docking with the corresponding connector 3.

[0361] Alternatively or additionally, as illustrated, the cover moulding 343 of the base 2 nay be extending to comprise a shroud 557 of substantially the same shape and form as the outer moulding 547 of the previous embodiment of the cordless connector 4 so that the shroud

557 acts to protect the resilient conductor 137E and acts as guidance during the docking.

The cover 343 may be manufactured in less expensive material for example polypropylene.

[0362] As illustrated at least part of the inlet of the moulding 535 of the control 60, 520, 676 may be removed and replaced by an extended skirt 19a that may be provided as part of the moulding of the sub base 19. As previously described a saving may be made by forming the inlet moulding 19a from the lower cost material of the sub base in comparison to the more expensive engineering type plastics of the control 60, 520, 676.

[0363] In further embodiments the trip lever 594 may be reliant upon the stability/integrity of the pivoting means 579 to maintain the closed condition of the switching means of the control 60, 520. The trip lever 594 may be configured to open the electrical contacts of the control 60, 520, for example a resilient spring contact 137, in the case that the interface between the trip lever 594 and the pivoting means 579 becomes compromised.

[0364] The pivot 579 may be associated with a part of the appliance 1 that may increase in temperature in response to an abnormal condition, for example the heater plate 12, if for example the appliance 1 is energised without liquid.

[0365] The pivot point 579 may comprise at least one element that is sensitive to increased temperature, for example a bimetal and/or melting fuse, which may compromise the integrity of the pivot point 925 when subjected to the temperatures of the abnormal condition and so result in the trip lever 594 opening the switching means in the control 60, 520, 676.

[0366] In further embodiments the trip lever 594 may comprise at least one element that is sensitive to increased temperature, for example a bimetal actuator and/or melting fuse, that may be biased against and/or associated with a part of the appliance 1 that may increase in temperature in response to an abnormal condition, for example the heater plate 12. The trip lever 594 may be configured to open the electrical contacts of the control 60, 520, for example a resilient spring contact 137, in response to the at least one element that is sensitive to increased temperature.

Alternative Embodiments

[0367] The embodiments described above are illustrative of rather than limiting to the present invention. Alternative embodiments apparent on reading the above description may nevertheless fall within the scope of the invention.

[0368] It is evident that the full scope and combination of embodiments is extensive; however it is envisaged that the skilled person, having read the description herein, will be able to transfer solutions between the embodiments to meet the specific problems of individual appliances within the scope of the present invention.

Alternative Clauses

[0369] Alternative statements of invention will now be recited in the following numbered clauses.

1. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the plug connector comprising a substantially central plug conductor for electrical connection to a corresponding socket conductor within a substantially central socket in the socket connector, the plug connector further comprising at least second and third conductors located outwardly of the substantially central plug conductor each at a different radial distance from the substantially central plug conductor, for electrical connection to corresponding conductors in the socket connector.

2. The cordless electrical connection system of clause 1, wherein said at least second and third conductors are circumferential conductors.

3. The cordless electrical connection system of clause 1 or 2, wherein the second and third conductors of the socket connector are separated by an annular wall.

4. The cordless electrical connection system of any one of clauses 1 to 3, arranged so that on connection of the plug and socket connectors, one conductor makes electrical contact before the other conductors.

5. The cordless electrical connection system of clause 4, wherein an earth conductor makes electrical contact before the other conductors. The cordless electrical connection system of any one of clauses 1 to 5, wherein at least one of the plug and socket connectors is waterproof.

The cordless electrical connection system of clause 6, wherein the at least one of the plug and socket connectors is made waterproof by sealing one or more cavities containing electrical connections to said conductors.

The cordless electrical connection system of any one of clauses 1 to 7, including an optical coupling permitting optical communications between the plug and socket connectors when connected.

A 3 or more conductor 360° cordless electrical connection system for electrical appliances in which the spatial requirements are reduced.

A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus comprising: a. a connector assembly including electrical connecting parts of the control; and b. a chassis assembly for connection to or forming part of the heating element plate; wherein the chassis assembly and the connector assembly are removably connected together; and wherein the connector assembly includes an earth connection removably connected or connectable to the chassis. The apparatus of clause 10, wherein the earth connection is removably connected to the chassis by resilient means. The apparatus of clause 10 or 11, wherein the earth connection comprises an annular member. The apparatus of clause 12, wherein the annular member is formed of sheet material. The apparatus of clause 13, wherein the sheet material is connected together by an interlocking joint. The apparatus of any one of clauses 10 to 14, wherein the chassis comprising clamping means for connection to the heating element plate and said clamping means further comprises an aperture to reduce the thermal path or thermal conduction between the heating element plate and the connector assembly.

16. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus comprising a chassis for mounting to the heating element plate, the chassis having an actuator mount for mounting at least one bimetallic actuator in proximity to the element plate, and having at least one resilient portion for resiliently mounting the chassis to the heating element plate, such that the proximity of the actuator to the plate is controlled by the final mounting position of the resilient chassis.

17. The apparatus of clause 16, wherein the chassis further includes a clamping means to resiliently deform and secure the resilient portion against the element plate and thereby control the proximity of the actuator to the element plate. 18. The apparatus of clause 17, in which a support for the at least one resilient portion acts as a backstop for the bimetal actuator so that the proximity of both the actuator and the actuator back stop to the element plate are controlled by the final mounting position of the resilient chassis.

19. The apparatus of clause 17 or 18 whereby the clamping means comprises no more than two discrete clamping points.

20. The apparatus of any one of clauses 16 to 19, wherein respective surfaces of the clamping means and the actuator mount for engaging and/or abutting the heating element plate are not coplanar.

21. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus comprising a chassis for mounting to the heating element plate, the chassis having an actuator mount for mounting at least one bimetallic actuator in proximity to the element plate, and having a clamping means for mounting the chassis to the heating element plate, wherein respective surfaces of the clamping means and the actuator mount for engaging and/or abutting the heating element plate are not coplanar, such that the proximity of the actuator to the plate is controlled by the actuator mount engaging and/or abutting the heating element plate. The apparatus of clause 21, wherein the clamping means comprises no more than two discrete clamping points

The apparatus of any one of clauses 15 to 22, wherein the clamping means further comprises an aperture to reduce the thermal path or thermal conduction between the heating element plate and the apparatus.

The apparatus of any one of clauses 10 to 23, wherein the chassis further comprises a rib or a raised portion for strengthening means.

A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus comprising a connector assembly including electrical connecting parts of the control, wherein at least one of said electrical connecting parts comprising a conductor stamped, folded and/or formed from a flat or sheet material to create a hollow central portion for receiving or containing a discrete contact. The apparatus of clause 25, wherein the discrete contact is provided at one end of the hollow central portion and the other end of the hollow portion comprises contact plate extending therefrom. The apparatus of clause 25 or 26, wherein the discrete contact is welded, soldered, brazed and/or crimped onto the hollow central portion. The apparatus of clause 25 or 26, wherein the discrete contact is welded, soldered or brazed to the flat or sheet material, and said material is stamped, folded and/or formed to form said hollow central portion for receiving or containing the discrete contact. The apparatus of any one of clauses 25 to 28, wherein the discrete contact is fed from a continuous length and cropped after being secured to the flat or sheet material or to the hollow central portion. The apparatus of any one of clauses 25 to 29, wherein the discrete contact is made from a low resistivity material. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus comprising: a. a connector assembly including electrical connecting parts of the control; and b. a chassis assembly for mounting to the heating element plate, the chassis assembly having an actuator mount for mounting at least one bimetallic actuator in proximity to the heating element plate, wherein the connector assembly includes a guide for receiving at least one push rod, in which the guide is arranged to guide movement of the push rod such that the deflection of the thermal bimetal blade is converted to a linear motion operable to disconnect the electrical connecting parts of the connector assembly. 32. The apparatus of clause 31, wherein the guide acts as insulation means between the chassis and the electrical connecting parts of the control assembly.

33. The apparatus of clause 31 or 32, wherein the guide clamps electrical connecting parts of the control assembly to a main moulding of the control assembly.

34. The apparatus of clause 33, wherein the guide is provided with at least one wall which in conjunction with said main moulding provides a shroud around the switching electrical connecting parts to prevent debris or other foreign matter entering this critical area.

35. The apparatus of clause 33 or 34, wherein the guide is removably attached to the main moulding.

36. The apparatus of any one of clauses 31 to 35, wherein the guide comprises at least one aperture for receiving at least one probe inserted therethrough for testing of the control assembly.

37. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising: a. a plug connector for said appliance; and b. a corresponding socket connector for said power base, wherein the plug connector comprises a main moulding having an annular passageway for engagement with the socket connector of the power base, and said main moulding having means for receiving an actuator for energising the appliance and a single resilient component to bias the actuator into an off position when the appliance is separated from the power base; and wherein the socket connector comprises a main moulding for engagement with said resilient component.

38. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising: a. a plug connector for said appliance; and b. a corresponding socket connector for said power base, wherein the plug connector comprises a main moulding having an annular passageway for engagement with the socket connector of the power base, and said main moulding having means for receiving an actuator for energising the appliance and a resilient component to directly bias the actuator into an off position when the appliance is separated from the power base; and wherein the socket connector comprises a main moulding for direct engagement with said resilient component.

39. The cordless electrical connection system of clause 37 or 38, wherein when the appliance is engaged with said power base the resilient component is urged away from the actuator so the actuator can operate in either the on and/or off position as required. 40. The cordless electrical connection system of any one of clauses 37 to 39, wherein said resilient component comprising one end secured to the main moulding of the plug connector and the other end for engagement with said main moulding of the socket connector.

41. The cordless electrical connection system of any one of clauses 37 to 40, wherein the resilient component comprises a fold or other feature to prevent damage or snagging when engaging and/or disengaging with the main moulding of the socket connector.

42. The cordless electrical connection system of any one of clauses 37 to 41, wherein the main moulding of the plug connector comprises an aperture to allow the resilient component to pass therethrough and into the annular passageway for engagement with the main moulding of the socket connector.

43. A thermal control apparatus for a cordless appliance, the control comprising a plug connector, including an annular passageway, for engagement with a socket connector of a power base, and having a single resilient component operable to engage an actuator on the appliance, wherein the single resilient component is arranged to force the actuator to an off position as the plug connector is separated from the socket connector to switch off the appliance.

44. A thermal control apparatus for a cordless liquid heating vessel, said vessel comprising an appliance proper with a heating element and a power base, said thermal control comprising an actuator operable to energise the heating element, said thermal control further comprising a single resilient component to bias the actuator into an off position when the appliance proper is separated from the power base and to bias the actuator into an off state when the appliance proper is engaged with said power base. 45. The apparatus of clause 43 or 44, wherein when the appliance is engaged with said power base the resilient component is urged away from the actuator so the actuator can operate in either the on and/or off position as required.

46. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus having a connector assembly comprising: a. a main moulding having an actuator mount for mounting at least one bimetallic actuator operable to be actuated by steam; and b. a bistable actuator pivotally mounted on said main moulding and operable to be actuated by said bimetallic actuator, wherein said actuator mount comprises a surface angled towards flow of the steam, for deflecting the steam flow towards the bimetallic actuator.

47. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus having a connector assembly comprising: a. a main moulding having an actuator mount for mounting at least one bimetallic actuator operable to be actuated by steam; and b. a bistable actuator having pivotally mounted on said main moulding and is operable to be actuated by said bimetallic actuator, wherein said apparatus comprises a surface angled towards flow of the steam, for deflecting the steam flow towards the bimetallic actuator. 48. The apparatus of clause 47, wherein the angled surface is provided on a sub base of said liquid heating vessel.

49. The apparatus of any one of clauses 46 to 48, wherein the main moulding comprises electrical connecting parts of the control and said bistable actuator is operable to disconnect the electrical connecting parts when the bistable actuator is in an off position. 50. The apparatus of any one of clauses 46 to 49, wherein the main moulding comprises a steam inlet for receiving the steam.

51. The apparatus of clause 50, wherein the steam inlet comprises a closed section to form a channel to guide the steam towards the angled surface.

52. The apparatus of clause 50, wherein the steam inlet is closed off with a separate component to form a closed section to channel the steam towards the angled surface. 53. The apparatus of clause 52, wherein the separate component is provided by a sub base of the liquid heating vessel.

54. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the socket connector comprising at least two apertures for receiving corresponding electrical conductors, and each aperture is provided with drainage means for draining liquids away from the respective apertures.

55. The cordless electrical connection system of clause 54, wherein the drainage means are arranged in a staggered or offset position from each other. 56. The cordless electrical connection system of clause 54 or 55, wherein the drainage means comprises separate drainage channels for each electrical conductors.

57. The cordless electrical connection system of any one of clauses 54 to 56, wherein the socket connector comprising at least three apertures for receiving corresponding electrical conductors. 58. The cordless electrical connection system of clause 57, when not made dependent to clause 56, wherein at least two apertures share a common and/or single drainage channel for the electrical conductors.

59. The cordless electrical connection system of any one of clauses 54 to 58, wherein the drainage means are channelled towards an aperture provided in the power base. 60. The cordless electrical connection system of clause 59, wherein the power base comprises an annular skirt that function as a weir and/or barrier to contain any excess liquid and divert this liquid towards the aperture.

61. The cordless electrical connection system of any one of clauses 54 to 60, wherein the power base comprises a cover moulding with an aperture and a substantially inwardly facing annular skirt having for receiving and engaging with the socket connector.

62. The cordless electrical connection system of any one of clauses 54 to 61, wherein the power base is provided with at least one shroud for mutually engaging with the drainage means.

63. The cordless electrical connection system of any one of clauses 54 to 62, wherein the body of the socket connector comprises an aperture for allowing liquids on the surface of the power base to enter the drainage means. The cordless electrical connection system of any one of clauses 54 to 63, wherein the power base further comprises a lower power base portion including means for receiving the socket connector. The cordless electrical connection system of clause 64 when dependent on clause 59, wherein the socket connector comprises locating means for mutually engaging with corresponding locating means provided on the lower power base portion for aligning the drainage means with the aperture provided in the power base. The electrical connection system of clause 64 or 65, wherein the socket connector comprises support means for mutually engaging with abutment means provided on the lower power base portion for aligning and/or indexing socket connector with the power base. The electrical connection system of any one of clauses 54 to 66, wherein the power base further comprises a base cover. The electrical connection system of 67, wherein the base cover further comprises an annular shroud forming a part of the socket connector for receiving the plug connector. The electrical connection system of clause 67 or 68, wherein the base cover comprises means for aligning and/or indexing the base cover with the lower power base portion. The electrical connection system of any one of clauses 67 to 69, when dependent on clause 63, wherein liquids on the surface of the base cover enter the aperture on body of the socket connector to be drained away via the aperture provided in the power base. The electrical connection system of any one of clauses 67 to 70, wherein the base cover further comprises is a removable cover portion. The electrical connection system of any one of clauses 64 to 71, wherein the lower power base portion comprises a plurality of series of electrical cable retention means forming a respective plurality of cable routes for receiving cables with different diameters. The electrical connection system of clause 72, wherein a series of electrical cable retention means are arranged in a staggered configuration. The cordless electrical connection system of any one of clauses 54 to 73, wherein the socket connector comprises at least one vertically extending conductor positioned externally of the socket connector. 75. The cordless electrical connection system of clause 74, wherein the at least one vertically extending conductor is housed within an individual shroud and/or annular skirt.

76. The cordless electrical connection system of clause 75, wherein the annular skirt forms a portion of a base cover for the power base.

77. An electrical conductor for a thermal control, the conductor having one end arranged to be mechanically and/or electrically connected to a cold tail of a heating element.

78. The electrical conductor of clause 77 wherein the conductor is formed from stamping of a continuous strip material.

79. The electrical conductor of clause 78, wherein the width of the conductor corresponds to the width of the continuous strip material.

80. The electrical conductor of any one of clauses 77 to 79, wherein the conductor comprises at least one fold or twist to at least plastically deform said conductor. 81. The electrical conductor of clause 80, wherein the at least one fold or twist provides a change in direction in at least one of the horizontal, axial, radial and/or vertical plane of the conductor.

82. The electrical conductor of clause 80 or 81, wherein the at least one fold or twist is provided to position the conductor for connection with the cold tail. 83. The electrical conductor of any one of clauses 77 to 82, wherein angular, axial, rotational and/or radial compliance is provided between the cold tails and the conductor.

84. The electrical conductor of any one of clauses 80 to 83when dependent from clause 78 or 79, wherein a portion of the conductor is folded to form an area wider than the strip material. 85. The electrical conductor of clause 84, wherein said wider area is formed at said one end of the conductor.

86. The electrical conductor of clause 84 or 85, wherein said wider area is mechanically and/or electrically connected to the connection means of heating element and/or switching means of the thermal control. 87. An arrangement comprising the electrical conductor of any one of clauses 77 to 86 and a securing means for electrically and/or mechanically securing said one end of the conductor to the cold tail, whereby the securing means comprises a clip and wherein contact forces for the electrically and/or mechanically connection is at least partially provided by the resilience of the clip.

88. The arrangement of clause 87, wherein the clip comprises a profile for cooperating with the cold tail.

89. The arrangement of clause 87 or 88, wherein at least one portion of the conductor and/or clip comprises positional features for restricting lateral movement of the clip relative to the conductor.

90. The arrangement of any one of clauses 87 to 89, wherein the clip and the conductor are configured to provide both compliance between the cold tail and the conductor and the contact forces to electrically and/or mechanically secure the cold to the conductor.

91. The arrangement of clause 90, wherein the compliance includes angular, axial, rotational and/or radial compliance between the cold tail and the conductor.

92. The arrangement of any one of clauses 87 to 91, wherein the clip is an electrical conductor.

93. The electrical conductor of any one of clauses 77 to 86, wherein said one end of the conductor comprises fixture means for mechanical and/or electrical connection to the cold tail.

94. The electrical conductor of clause 93, further comprising an aperture for receiving the cold tail and at least one resilient barb arranged in a radial and/or linear configuration relative to the aperture, for engaging the cold tail for mechanical and/or electrical connection. 95. The electrical conductor of clause 94, wherein the at least one resilient barb provides compliance between the cold tail and the conductor.

96. The electrical conductor of any one of clauses 93 to 95, wherein the cold tail further comprises retention means for engaging with said at least one resilient barb to retain the conductor on the cold tail. 97. The electrical conductor of clause 96, wherein said retention means comprises at least one indent or protrusion. 98. The electrical conductor of any one of clauses 77 to 97, wherein the conductor further comprises a series of folds to provide compliance between the connection means and the conductor.

99. The electrical conductor of any one of clauses 77 to 98, wherein the conductor further comprises a tab terminal for providing electrical power to auxiliary components.

100. The electrical conductor of any one of clauses 77 to 99, wherein the conductor further comprises at least one portion for carrying at least one switch contact for the control.

101. An electrical connector means for connecting a conductor to a cold tail of a heating element, wherein the connector comprises a clip, whereby the contact forces for the electrically and/or mechanically connection are partially provided by the resilience of the clip.

102. The electrical connector means of clause 101, wherein the clip comprises a profile for cooperating with the cold tail. 103. The electrical connector means of clause 101 or 102, wherein one end of the conductor and/or clip comprises positional features for restricting lateral movement of the clip relative to the conductor.

104. The electrical connector means of any one of clauses 101 to 103 wherein the clip and the conductor are configured to provide both compliance between the cold tail and the conductor and the contact forces for electrically and/or mechanically securing the clip to the conductor.

105. The electrical connector means of clause 104, wherein the compliance includes angular, axial, rotational and/or radial compliance between the cold tail and the conductor. 106. The electrical connector means of any one of clauses 101 to 105, wherein the clip is an electrical conductor. [RSI]

107. A thermal control apparatus for a liquid heating vessel comprising a thermal control having an actuator cooperating with a mounting means for operating a heating element between at least two states, wherein the mounting means is arranged to bias the actuator to an off state in response to an overheat condition of the heating element. 108. The thermal control of clause 107, wherein the mounting means comprises a pivotal connection means.

109. The thermal control of clause 107 or 108, wherein the mounting means comprises at least one element that is sensitive to an increase in temperature of the heating element.

110. The thermal control of clause 109, wherein the at least one element is a mechanical thermal actuator.

111. The thermal control of clause 110, wherein the mechanical thermal actuator is a bimetal.

112. The thermal control of clause 109, wherein the at least one element is a thermal fuse material.

113. An pivoting actuator for a liquid heating vessel, wherein the pivoting means biases the actuator to an off state in response to an overheat condition of the heating element. [RS2]

114. A substantially 360° cordless electrical connection system of any one of clauses 1 to 9 comprising at least: a. the thermal control of any one of clauses 10 to 15; b. the thermal control of any one of clauses 16 to 20; c. the thermal control of any one of clauses 21 to 24; d. the thermal control of any one of clauses 25 to 30; e. the thermal control of any one of clauses 31 to 36; f. the connection system of any one of clauses 37 to42; g. the thermal control of any one of clauses 43 to 53; h. the connection system of any one of clauses 54 to 76; i. the electrical conductor of any one of clauses 77 to 86 or 93 to 100; j. the arrangement of any one of clauses 87 to 92; k. the electrical connector means of any one of clauses 101 to 106; 1. the thermal control of any one of clauses 107 to 112; and/or m. the pivoting actuator of clause 113. Furnished blank upon filing

Claims

1. A substantially 360° cordless liquid heating appliance and a corresponding power base wherein the appliance comprises a thermal control mounted to a heating element and the thermal control having at least one of the following:

b. a chassis for mounting the thermal control to the heating element

c. an actuator in response to steam to switch off the thermal control in response to the temperature of the liquid to be heated;

d. at least one bimetallic actuator mounted on the chassis, to switch off the thermal control in response to an over temperature condition of the heating element; e. a pivotal actuator operable to operate a switching means between at least two states; and

2. The cordless liquid heating appliance of claim 1, wherein when the appliance is engaged with said power base the resilient component is urged away from the pivotal actuator so the pivotal actuator can operate in either the on and/or off state as required.

3. The cordless liquid heating appliance of claim 1 or 2, wherein said resilient component comprising one end secured to the electrical plug connector and the other end for engagement with said the electrical socket connector and/or said portion of the power base.

4. The cordless liquid heating appliance of any one of claims 1 to 3, wherein the resilient component comprises a fold or other feature to prevent damage or snagging when engaging and/or disengaging with the electrical socket connector and/or said portion of the power base.

5. The cordless liquid heating appliance of any one of claims 1 to 4, wherein the electrical plug connector comprises an aperture to allow the resilient component to pass therethrough and into the annular passageway for engagement with the electrical socket connector and/or portion of the power base.

6. The cordless liquid heating appliance of any one of claims 1 to 5, wherein the single resilient component is arranged to force the pivotal actuator to an off position as the electrical plug connector is separated from the electrical socket connector and/or portion of the power base to switch off the appliance.

7. The cordless liquid heating appliance of any one of claims 1 to 6, wherein the electrical conductor is a flat electrical conductor formed from stamping of a continuous strip material.

8. The cordless liquid heating appliance of claim 7, wherein the flat electrical conductor comprises at least one fold or twist to at least plastically deform said flat electrical conductor, whereby the at least one fold or twist provides a change in direction in at least one of the horizontal, axial, radial and/or vertical plane of the flat electrical conductor.

9. The cordless liquid heating appliance of claim 7 or 8, wherein angular, axial, rotational and/or radial compliance is provided between the cold tails and the flat electrical conductor.

10. The cordless liquid heating appliance of any one of claims 7 to 9, further comprising a clip for electrically and/or mechanically securing said one end of the flat electrical conductor to the cold tail, wherein contact forces for the electrically and/or mechanically connection is at least partially provided by the resilience of the clip.

11. The cordless liquid heating appliance of claim 10, wherein the clip and the flat electrical conductor are configured to provide both compliance between the cold tail and the conductor and the contact forces to electrically and/or mechanically secure the cold to the conductor, wherein the compliance includes angular, axial, rotational and/or radial compliance between the cold tail and the flat electrical conductor.

12. The cordless liquid heating appliance of any one of claims 1 to 9, wherein the electrical conductor further comprises an aperture for receiving the cold tail and at least one resilient barb arranged in a radial and/or linear configuration relative to the aperture, for engaging the cold tail for mechanical and/or electrical connection.

13. The cordless liquid heating appliance of claim 12, wherein the cold tail further comprises retention means for engaging with said at least one resilient barb to retain the electrical conductor on the cold tail.

14. A thermal control apparatus for a liquid heating vessel having a heating element plate, the thermal control apparatus comprising a chassis for mounting to the heating element plate, the chassis having an actuator mount at one end for mounting at least one bimetallic actuator in proximity to the heating element plate, a support portion at the other end of the chassis, wherein the actuator mount and the support means are arranged to support the chassis against the heating element plate in use, and having at least one resilient portion provided between the actuator mount and the support means for resiliently supporting the chassis against the heating element plate.

15. The thermal control apparatus of claim 14, further comprising clamping means for resiliently deforming and securing the resilient portion against the heating element plate and thereby control the proximity of the actuator to the element plate.

16. The thermal control apparatus of claim 14 or 15, wherein respective surfaces of actuator mount, support portion and resilient portion for engaging and/or abutting against the heating element plate are not coplanar prior to securing the resilient portion against the heating element plate.

17. The thermal control apparatus of claim 15, in which a support for the at least one resilient portion acts as a backstop for the bimetal actuator so that the proximity of both the bimetal actuator and the backstop to the element plate are controlled by the final mounting position of the chassis.

18. The thermal control apparatus of any one of claims 15 to 17, whereby the clamping means comprises no more than two discrete clamping points.

19. A thermal control apparatus for a liquid heating vessel having a heating element plate, the apparatus having a connector assembly comprising: a. a main moulding having an actuator mount for mounting at least one bimetallic actuator operable to be actuated by steam; and b. a bistable actuator having pivotally mounted on said main moulding and is operable to be actuated by said bimetallic actuator, wherein said thermal control apparatus comprises a surface angled towards flow of the steam, for deflecting the steam flow towards the bimetallic actuator, wherein the angled surface is provided on the control or a sub base of said cordless liquid heating vessel.

20. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the socket connector comprising at least two apertures for receiving corresponding electrical conductors, and each aperture is provided with drainage means for draining liquids away from the respective apertures, wherein the power base comprises an annular skirt that functions as a weir and/or barrier in conjunction with an annular channel provided in the socket connector to contain any excess liquid and divert this liquid towards an aperture.

21. A substantially 360° cordless electrical connection system for connecting an appliance to a power base, the system comprising a plug connector and a corresponding socket connector, the socket connector comprising at least two apertures for receiving corresponding electrical conductors, wherein the socket connector comprises at least one vertically extending conductor positioned externally of the at least two apertures of the socket connector. .

22. The cordless electrical connection system of claim 21, wherein the at least one vertically extending conductor is housed within an individual shroud and/or annular skirt.

23. The cordless electrical connection system of claim 22, wherein the power base comprises a base cover, and wherein the annular skirt forms a portion of the base cover.