AU2010200571B2 - Improved temperature sensor for an electric heating appliance - Google Patents

Abstract

A kettle for heating water located in a heating chamber includes a contact plate (78) defining a base of the heating chamber and having a contact surface that, in use, is in direct thermal communication with the water when located in the heating chamber. A 5 heat distribution plate (80) is in thermal communication with the contact plate, the heat distribution plate defining a void (88) that provides a thermally-insulating zone surrounded by the heat distribution plate. A heating element (20) is in thermal communication with the heat distribution plate and an electronic temperature sensor (82) is located within the thermally insulating zone in thermal communication with the 10 contact plate, the electronic temperature sensor being thermally insulated from the heat distribution plate by the thermally-insulating zone. A heat-source controller controls the heating element responsive to a temperature sensed by the electronic temperature sensor. The heat distribution plate may be provided with a plurality of ribs (86) and the thermally-insulating zone may include a plurality of voids (88) defined by the heat 15 distribution plate and said ribs. The void may be defined by a portion (92) of the heat distribution plate having a reduced thickness relative to a thickness of a region of the heat distribution plate adjacent to said portion. Figure 1

Description

Regulaon 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Invention Title: Improved temperature sensor for an electric heating appliance The following statement is a full description of this invention, including the best method of performing it known to us: 2 Improved temperature sensor for an electric heating vessel Field of the invention The present invention relates to heating vessels and in particular to heating vessels that include temperature sensors for accurately detecting the temperature of the heating 5 vessel's contents during operation. Background of the invention Heating vessels (such as kettles, percolators, mocha makers, rice cookers, slow cookers and electric fry ware) are commonly used to prepare food and drinks. These heating vessels generally include an electric heating element which heats a contact 10 plate via a heat distribution plate. The heating surface of the contact plate is in direct contact with the vessel's contents. Normally the heating vessel has a temperature sensor to sense the temperature of the vessel's contents. The temperature detected is used to control the operation of the heating vessel. For instance, a kettle has a temperature sensor to detect when water in 15 the kettle is boiling. In the case of a kettle, the temperature sensor is often a mechanical sensor such as a snap-action bimetallic actuator which turns the kettle off once the water has boiled. In some arrangements the temperature sensor is mounted to the heat distribution plate. This mounting location greatly reduces the accuracy of the temperature sensor. The 20 temperature sensor senses the temperature of the heat distribution plate and does not directly sense the temperature of the vessel's contents. Because of this, discrepancies may arise between the measured temperature and the actual temperature of the contents. For a kettle, this may result in the kettle switching off before the water is actually boiling. 25 An inaccurate temperature sensor limits the potential functionality of the heating vessel. Since the temperature of the vessel's contents is not accurately sensed, only a limited range of functions controlled with reference to an approximate temperature reading are 3 possible. For example, in the case of a kettle, it is only possible to stop the kettle boiling based on an approximate boiling point. Reference to any background art in the specification is not an acknowledgement or any form of suggestion that this background art forms part of the common general 5 knowledge in Australia or any other jurisdiction or that this background art could reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art. Summary of the invention According to a first aspect of the invention there is provided a kettle for heating water 10 located in a heating chamber of the kettle, the kettle including: (a) a contact plate defining a base of the heating chamber and having a contact surface that, in use, is in direct thermal communication with the water located in the heating chamber of the kettle; (b) a heat distribution plate in thermal communication with and welded to the 15 contact plate, wherein the heat distribution plate is thicker than the contact plate and has a thermal conductivity that is higher than a thermal conductivity of the contact plate, the heat distribution plate defining at least one void that provides a thermally-insulating zone surrounded by the heat distribution plate; (c) a curved resistive heating element ending in a pair of cold tails, the 20 heating element welded to a peripheral region of the heat distribution plate in thermal communication with the heat distribution plate; (d) an electronic temperature sensor located within the thermally insulating zone in thermal communication with the contact plate, the electronic temperature sensor being thermally insulated from the heat distribution plate by the thermally 25 insulating zone, the electronic temperature sensor sensing temperature in a continuous range; (e) a controller for controlling the heating element; and (f) a button arrangement in communication with the controller for a user to select between different heating modes of the controller, wherein the controller 30 controls the heating element responsive to the temperature sensed by the electronic temperature sensor and the controller activates the different heating modes dependent on a selection made using the button arrangement, wherein 1001283740 4 the heat distribution plate is provided with a plurality of ribs and the thermally insulating zone includes a plurality of voids defined by the heat distribution plate and said ribs. The kettle may comprise a heat-source controller for controlling the heating element 5 responsive to a temperature sensed by the electronic temperature sensor. The kettle may have a keep-warm mode in which the heat-source controller acts to maintain the temperature sensed by the electronic temperature sensor substantially at a specified warm temperature. The kettle may also have a boil mode for heating the temperature sensed by the electronic temperature sensor to a specified boil 10 temperature, the kettle having a button arrangement comprising a keep-warm button and a boil button operable for a user to select from the keep warm mode and the boil mode, wherein the heat-source controller controls the heating element responsive to the temperature sensed by the electronic temperature sensor and dependent on a selection made using the button arrangement. 15 The heat distribution plate may be provided with a plurality of ribs and the thermally insulating zone includes a plurality of voids defined by the heat distribution plate and said ribs. The void may be defined by a portion of the heat distribution plate having a reduced thickness relative to a thickness of a region of the heat distribution plate adjacent to said 20 portion. Said portion having reduced thickness may be adjacent said contact plate. According to a further aspect of the invention there is provided A kettle for heating water located in a heating chamber of the kettle, the kettle including: (a) a contact plate defining a base of the heating chamber and having a contact 25 surface that, in use, is in direct thermal communication with the water located in the heating chamber of the kettle; (b) a heat distribution plate in thermal communication with and welded to the contact plate, wherein the heat distribution plate is thicker than the contact plate and has a thermal conductivity that is higher than a thermal conductivity of the 30 contact plate, the heat distribution plate defining at least one void that provides a thermally-insulating zone surrounded by the heat distribution plate; 1001283740 4a (c) a curved resistive heating element ending in a pair of cold tails, the heating element welded to a peripheral region of the heat distribution plate in thermal communication with the heat distribution plate; 5 (d) an electronic temperature sensor located within the thermally insulating zone in thermal communication with the contact plate, the electronic temperature sensor being thermally insulated from the heat distribution plate by the thermally insulating zone, the electronic temperature sensor sensing temperature in a continuous range; 10 (e) a controller for controlling the heating element; and (f) a button arrangement in communication with the controller for a user to select between different heating modes of the controller, wherein the controller controls the heating element responsive to the temperature sensed by the electronic temperature sensor and the controller activates the different heating modes 15 dependent on a selection made using the button arrangement, wherein the at least one void is defined by a portion of the heat distribution plate having a reduced thickness relative to a thickness of a region of the heat distribution plate adjacent to said portion. Brief description of the drawings 20 Embodiments of the invention will now be described with reference to the drawings, in which: Figure 1 is a cross-sectional drawing of an electric kettle; Figure 2 is a partially cut-away view of a heater assembly for the kettle of Figure 1; 25 Figure 3 shows more detail of the heater assembly of Figure 2 including an electronic temperature sensor and heat-source controller; Figure 4 shows a cross-sectional view of part of the heater assembly; 1001283740 5 Figure 5 shows an arrangement in which the heater assembly is positioned on a concave contact plate of the kettle; Figure 6 shows an arrangement in which the heater assembly is positioned on a convex contact plate of the kettle; 5 Figure 7 shows a button arrangement for controlling 'boil' and 'keep warm' operating modes for the kettle, the button arrangement including indicators of the state of the kettle; Figure 8 is a graph illustrating the operation of the kettle in the boil mode; Figure 9 is a graph illustrating the operation of the kettle in the 'keep warm' 10 mode; Figure 10 is a graph illustrating the effect of adding water to the kettle during the keep warm mode; Figures 11 and 12 are graphs comparing the temperature of water in the kettle with the temperature measured by the temperature sensor of Figure 2; 15 Figure 13 is a graph comparing the performance of the kettle of Figures 1 to 7 with the performance of a standard kettle; Figure 14 shows a bottom view of an alternative heater assembly for use in the kettle of Figure 1; Figure 15 shows a cross-sectional side view of the heater assembly of Figure 14; 20 Figure 16 shows a further view of the heater assembly of Figure 14, illustrating the threaded mounting of a temperature sensor; Figure 17 is a flow diagram illustrating a method of selecting the cut-off temperature dependent on the load in the kettle; 6 Figure 18 provides a partial plan schematic of a heat distribution plate with a thermally insulating zone in accordance with an alternative embodiment of the invention; Figure 19 provides a perspective view of the heat distribution plate of Figure 18; Figure 20 provides a partial cross-sectional schematic of a heat distribution plate 5 with a thermally insulating zone in accordance with a further alternative embodiment of the invention; Figure 21 provides a perspective view of the heat distribution plate of Figure 20; and Figure 22 provides an alternative embodiment of the heat distribution pate of 10 Figures 20 and 21. Detailed description of the embodiments Figure 1 shows a cross-sectional view of an electric kettle 10. The electric kettle has a heating chamber 12, which holds the water to be boiled. The water may be poured into the heating chamber 12 of the kettle through the pouring spout 14. The base wall of the 15 heating chamber 12 is defined by a contact plate 16. Water stored in the heating chamber 12 is in direct contact with one side of the contact plate 16. The contact plate 16 may be formed from stainless steel. Other materials which are suitable for contacting water and are resistant to high temperatures and oxidation may be used. The contact plate 16 forms part of a heater assembly 18. The heater assembly is 20 generally located underneath the heating chamber 12 on the opposite side of the contact plate to the heating chamber 12. One embodiment of the heater assembly 18 is shown in greater detail in Figures 2 to 4. The heater assembly 18 is powered by a power source (not shown) which is external to the kettle 10. The power may be transmitted to the heater assembly 18 using known techniques, for instance through a 25 plug-in electrical lead.

7 The heat used to boil the water is generated by a heating element 20, which is curved and terminates in cold tails carrying electrical connections 22. Preferably the heating element 20 is powered by electricity. The heating element 20 shown is a resistance element. Other types of heating elements may be used. 5 The heating element 20 is bonded to a heat distribution plate 24. The bonding achieves a good thermal coupling between the heating element 20 and the heat distribution plate 24 so that heat generated by the heating element 20 is rapidly and efficiently transferred to the heat distribution plate 24. Many known bonding techniques are suitable, including induction welding, flame or oven welding and impact welding. Alternatively the heating 10 element 20 may be mounted to the heat distribution plate 24 using other known techniques, such as mechanical fasteners. The heat distribution plate 24 is induction brazed to the contact plate 16 so there is a good thermal coupling between the heat distribution plate 24 and the contact plate 16. Many other known bonding techniques are suitable, including the bonding techniques 15 mentioned above. Alternatively the heat distribution plate 24 may be mounted to the contact plate 16 using other known techniques, such as mechanical fasteners. The heat distribution plate 24 may be formed from aluminium, which is a good thermal conductor, and is of sufficient thickness so that heat is evenly distributed over the contact plate 16. Alternative materials for the heat distribution plate 24 include other 20 metals and metal alloys. The heat distribution plate 24 is generally thicker than the contact plate and formed from a material which is a better thermal conductor than the contact plate. The heat distribution plate 24 defines a void 26. The void 26 forms a thermally insulating zone. This is because heat which is transmitted from the heating element 20 to the heat 25 distribution plate 24 is not as readily transmitted across the void 26. The region of the contact plate 16 located adjacent the void 26 does not conduct significant amounts of heat when compared to the aluminium heat distribution plate 24 because the contact plate 16 is thin and formed from stainless steel, which is not as good a thermal conductor.

8 Mounted in the void 26 is an electronic temperature sensor 28. The void 26 provides a thermally insulating zone around the electronic temperature sensor 28. Heat from the heat distribution plate 24 is not readily transmitted to the electronic temperature sensor 28. As a result, the electronic temperature sensor 28 is thermally insulated and is not 5 undesirably influenced by the temperature of the heating element 20 and heat distribution plate 24. Preferably the thermally insulating zone and the temperature sensor 28 are located between the cold tails 22 of the heating element 20. The cold tails do not generate significant amounts of heat, so the electronic temperature sensor 28 is further insulated 10 from the heat generated by the heating element 20. Instead of being empty, the void 26 may be filled, either partially or wholly, with an insulating material, such as silicone or rubber. The temperature sensor 28 is mounted in close proximity to the contact plate 16. Optionally, the temperature sensor 28 may be touching the contact plate 16. This 15 improves the thermal coupling between the electronic temperature sensor 28 and the contact plate 16. The thermal coupling may be further improved using known techniques, such as applying a heat transfer paste. It is an advantage that the temperature sensor 28 is in thermal contact with the contact plate 16 in the region indicated by 29. When water contained in the heating chamber 12 20 of the kettle 10 heats up, the contact plate 16 will heat to a similar temperature. Due to the void 26, the region of the contact plate 16 located within the void is insulated from the heat distribution plate 24 and will more accurately reflect the temperature of the water. Since the temperature sensor 28 is in thermal communication with the contact plate 16, it senses the water temperature with greater accuracy and responsiveness. 25 Figures 2 to 4 show the temperature sensor 28 being supported by a sensor support 30. The sensor support 30 is formed from silicone, and is held in place by a bracket 32. Other insulating materials are also suitable. The bracket 32 is mechanically fastened to the heat distribution plate 24 and is preferably formed from a relatively rigid material, such as a plastic, metal or metal alloy. The bracket 32 locates the sensor support 30 in 9 the centre of the void 26 so the sensor 28 is insulated and may press the sensor support 30 against the contact plate 16, providing a good thermal connection between the sensor 28 and the contact plate 16. The temperature sensor 28 may be mounted in a number of ways which aim to reduce the influence of heat from the heat distribution 5 plate 24. The temperature sensor 28 is typically a thermistor. NTC thermistors formed from metal oxides are suitable. A thermistor has a number of advantages over other types of temperature sensors. A thermistor senses the temperature of water in the kettle within a continuous range. This provides significantly more information on the temperature of the 10 water than, for example, a bimetallic actuator. A bimetallic actuator is typically activated only when the water reaches a threshold temperature value and is deactivated when the water falls below a threshold temperature value. As a result, a bimetallic actuator only senses whether the water temperature is above or below a threshold value. The thermistor provides responsive and accurate readings because it is mounted in a 15 thermally insulating zone in direct thermal communication with the contact plate 16. The heater assembly 18 shown in Figures 2 to 4 has a single void 26 in which the temperature sensor 28 is located. As discussed further below (with reference to figures 18 to 22), alternative means of reducing heat transfer between the heat distribution plate 24 and the temperature sensor 28 are possible. For example, it is also possible to 20 have multiple voids around the temperature sensor, each void forming a thermally insulating region. By positioning a number of the thermally insulating regions around the sensor 28, a thermally insulating zone is formed. The sensor 28 is still mounted in direct thermal contact with the contact plate 16. In one arrangement the contact plate 16 is indent-free. The contact plate 16 shown in 25 Figures 2 to 4 is indent-free at least in the region of the temperature sensor 28. This shape may improve the accuracy of the temperature sensor 28. Because the contact plate 16 is indent free, water contained in the heating chamber 12 of the kettle 10 is able to readily and rapidly mix. This means the temperature of water located immediately above the temperature sensor 28 is more likely to accurately reflect the 30 temperature of the remaining water volume contained in the kettle 10. Consequently the 10 temperature sensor 28 gives more accurate readings of the temperature of all of the water in the kettle 10. Alternative arrangements are shown in Figures 5 and 6, in which the contact plate is not uniplanar but is nevertheless free of indents in the region of the temperature sensor 28. 5 Figure 5 shows a concave contact plate 33 which is curved towards the heater assembly 18 in the centre of the contact plate. Figure 6 shows a convex contact plate 35 which is curved away from the heater assembly 18 in the centre of the contact plate. In the case of Figure 6, the convex curvature of the contact plate 16 results in the temperature sensor 28 protruding into the heating chamber 12 of the kettle 10 by a 10 greater amount than other regions of the contact plate 16. Since the cold water tends to collect in the lower-most volumes of the heating chamber 12, water located opposite the sensor 28 is more likely to reflect the average temperature of the water contained in the kettle 10. This may improve the accuracy of temperature readings made by the sensor 28. In further arrangements (not illustrated) the contact plate 16 has a dome-shaped 15 protrusion in the region adjacent the temperature sensor 28. The dome formed in the contact plate 16 may extend into the heating chamber 12 or, alternatively, may extend away from the heating chamber. Referring again to Figures 2 to 4, the heater assembly 18 has a heat-source controller 34. The heat-source controller is electronically connected to the temperature sensor 28 20 and the heating element 20. The heat-source controller 34 controls the operation of the heating element 20 with reference to the temperature sensed by the temperature sensor 28. Preferably, the controller 34 consists of an electronic circuit or number of electronic circuits. These circuits may be designed in a number of ways to provide the functionality described below. The controller 34 preferably includes a microprocessor. 25 The heat-source controller may have a number of different functions, such as a boil function and a "keep warm" function, which use feedback from the temperature sensor 28. These functions are made possible because the temperature sensor 28 is able to accurately sense the temperature of the water contained in the kettle 10 within a large range. For example, the temperature sensor 28 may have an operating range between 30 0*CandlO0 0

C

11 The functions of the kettle 10 are operated by button arrangement 36 which is shown in Figure 7. The button arrangement 36 consist of a "boil" button 38 and a "keep warm" button 40, both of which are momentary push buttons. The buttons 38, 40 may alternatively be a variety of other button types. A ring 42, 44 around each button is 5 translucent. These rings are illuminated by LEDs to provide a user with information regarding the kettle's operation. The LEDs are optionally LEDs capable of emitting different coloured lights, for example to indicate temperature levels in the kettle. Other types of lights may be used, such as a conventional filament bulb. A "standby" LED 46 is illuminated when the external power is connected to the kettle. The buttons are 10 connected to, and provide input to, the controller 34. The lights are connected to, and are operated by, the controller 34. When the boil button 38 is activated, the controller 34 enters a boil mode, graphically displayed in Figure 8. Before activation, the controller 34 is in a standby mode (indicated by "Area 1" in Figure 8). After activation, the controller 34 enters the boil 15 mode (indicated by "Area 2" in Figure 8). When in the boil mode, the controller 34 turns on the heating element 20, which begins to heat the water in the kettle. The controller 34 additionally causes the illuminated ring 42 to produce, for example, red light, to indicate the controller is in the boil mode and the water is being boiled. The temperature sensor 28 detects when an upper boiling limit has been reached. The 20 upper boiling limit may be 97*C, though other limits are also suitable. At this point the controller enters a "boiled" mode (indicated by "Area 3" in Figure 8). In the boiled mode, the controller turns off the heating element 20 and the red light in the illuminated ring 42. The controller then turns on, for example, a green light in the illuminated ring 42 to indicate that the water is boiled. 25 In the boiled mode, the temperature sensor 28 continues to sense the temperature of the water. After the heating element 20 is turned off, the water slowly cools. Once the temperature of the water falls to a lower boiling limit, the controller ends the "boiled" mode and returns to "standby" mode (indicated by "Area 4" in Figure 8). At this stage, the controller turns off the green light in the illuminated ring 42 to indicate the water is 12 no longer at or near boiling temperature. A suitable lower boiling limit is 92 0 C, though other limits are also suitable. When the "keep warm" button 40 is activated, the controller 34 enters a keep warm mode in which the water is first boiled and then maintained at a warm average 5 temperature, for example about 85 "C. The keep warm mode is graphically illustrated in Figure 9. Prior to activation, the controller is in the standby mode (indicated by "Area 1" in Figure 9) and the water is at ambient temperature. In the keep warm mode (indicated by "Area 2" in Figure 9), the controller 34 turns on the heating element 20. This heats the water as described previously. The controller 34 also causes a, for example, amber 10 light to illuminate the illuminated ring 44 to indicate that the controller 34 is in the keep warm mode. The heating element 20 continues to heat the water until the temperature sensor 28 detects the water temperature has reached an upper boiling limit, indicated at reference numeral 50. The heating element 20 is switched off and the water in the kettle cools 15 gradually until a lower warm limit is reached, as indicated at reference numeral 52. A suitable lower warm limit is 83 *C, although other values may be used. The controller 34 then switches the heating element 20 back on and the water temperature rises until an upper warm limit is reached (see reference numeral 54). A suitable upper warm limit is 87*C, though other limits are also suitable. When this occurs, the controller 34 turns off 20 the heating element 20. This process continues so that the water temperature oscillates between the upper warm limit and the lower warm limit, keeping the water at an average temperature. The keep warm mode continues until the keep warm button 40 is pressed to deactivate the keep warm mode. If the kettle is about to boil dry (that is, the water in the kettle has 25 substantially evaporated), the temperature detected by the sensor 28 increases rapidly. If this rapid increase is detected, the controller 34 deactivates the keep warm mode and resumes the standby mode to avoid the kettle boiling dry. Alternatively, the keep warm mode may be ended automatically after four hours.

13 In one arrangement the kettle 10 may have two or more heating modes dependent on the load, i.e. the amount of liquid in the kettle. Low volumes of liquid heat up more rapidly than larger volumes. The controller 34 monitors the measured temperature and determines the rate of change of the measured temperature. The controller 34 selects a 5 heating mode based on the rate of change. If low volumes are deduced (i.e. the rate of change of temperature lies in a specified higher range), then the heating element 20 is switched off at a reduced upper boiling limit. In the boil mode, a reduced upper boiling limit of 93'C is suitable, although other values may be used. If the controller 34 deduces that higher volumes of liquid are present (i.e. the rate of 10 change of temperature lies in a specified lower range), the heating element 20 is switched off at a higher boiling limit, for example 970C. The controller 34 monitors the rate of change of measured temperature on a regular basis and, if necessary, selects a different upper boiling limit based on the current rate of change. Thus, for example, if cold water is added to the kettle 10, the controller 34 15 may need to switch to a heating mode that uses a higher cut-out temperature. Two or more heating modes may be established. For the boil mode, the controller 34 may have a look-up table that lists a suitable upper boiling limit corresponding to different rates of heating. In one arrangement the lower boiling limit may also be reduced for the case of low volumes. For example, the lower boiling limit may be set 20 40C lower than the selected upper boiling limit. In the keep warm operation, the controller 34 may also select a different upper boiling limit depending on the rate of change of temperature. In alternative arrangements the load may be inferred from measurements other than the rate of change of temperature. Such alternative load measurements include the level of 25 liquid in the kettle or the weight of the kettle. For example, a reed switch or capacitive sensor may be used to indicate the level in the kettle. In such an arrangement, the controller 34 may select a higher or lower boiling limit dependent on whether the level of fluid is above or below a threshold value.

14 Figure 17 illustrates a method 200 of selecting the upper boiling limit. In step 202 the temperature sensor 28 generates a temperature signal that is related to the temperature of the water in the kettle 10. In step 204 a load signal is generated that is related to the amount of liquid in the kettle. In the preferred arrangement the controller 34 generates 5 the load signal by monitoring the rate of change of the measured temperature, thereby deducing the load of the kettle. Based on the load signal, in step 206 the controller 34 selects a threshold value to use as the upper boiling limit. The threshold value may be read from a look-up table stored in memory. In step 208 the controller 34 acts to switch off the heating element 20 if the temperature signal is greater than or equal to the 10 threshold value. Figure 10 shows the kettle 10 being refilled whilst the keep warm mode is activated. To refill the kettle, it may be disconnected from the external power supply. When this occurs, power to the controller 34 is disrupted. The controller 34 has an electronic memory which stores an indication of whether the controller is in the boil mode and / or 15 the keep warm mode. The memory is preferably EPROM, though other types of memory may be used. Once the kettle is refilled, it is reconnected to the external power supply. The controller 34 then resumes the mode or modes which are stored in the memory. When the kettle is refilled, the temperature of the water in the kettle drops rapidly, as 20 indicated at reference numeral 56 in Figure 10. When the controller 34 resumes the keep warm mode, the water is reheated until the upper warm limit is reached. The keep warm mode then continues as before. A similar process occurs if the kettle is refilled whilst in the boil mode. The kettle may also have a audible indicator (not shown) for providing an audible 25 indication of which mode the controller is in. The controller mode indicator may be one or more buzzers or speakers. The controller mode indicator is connected to, and operated by the controller 34. The additional functionality described above is made possible by the arrangements described herein. These arrangements provide a temperature sensor which is able to 15 accurately and responsively detect the temperature of water contained in the kettle. Without responsive and accurate temperature sensing, the boil mode and keep warm mode described above may not function properly. Figures 11 and 12 graphically show the accuracy and responsiveness of the temperature sensor. In these Figures, the 5 darker line 3 represents the water temperatures and the line 4 represents the temperatures sensed by the temperatures sensor. As can be seen, the two lines are closely matched. Figure 13 shows a comparison between the temperature sensed during boiling by a temperature sensor in a conventional kettle (denoted "STD Kettle" in Figure 13) and a 10 temperature sensor in a kettle using the arrangements described herein (denoted "Elec Kettle" in Figure 13). The same volume of water and heating power is used in each case. Once the water has boiled, each of the kettles switches off its respective heating element. However, the time between the water boiling and the heating element switching off is different in the two cases. As seen in Figure 13, for a standard kettle the 15 heating element stays on for a relatively long duration after the water boils, as indicated at reference numeral 60. In contrast, for the electronic kettle 10, the heating element 20 stays on for a shorter time, as indicated at reference numeral 58. With repeated use, this difference may represent a significant energy saving in the electric kettle 10 compared with the standard kettle. The improvement in performance is enabled by the 20 greater accuracy of the temperature arrangement described herein compared with the bimetallic switch used in the standard kettle. Figures 14 to 16 show an alternative heater assembly 60. The heater assembly 60 has a heating element 62, a heat distribution plate 64, a contact plate 66, a controller 68 and an electronic temperature sensor 70 which are similar in description and function to 25 those described in relation to Figures 2 to 6. The heat distribution plate 64 has a toroidal void 72. The void 72 forms a thermally insulating zone around the temperature sensor 70, for the reasons described above. The portion of the heat distribution plate located in the centre of the void 72 is a sensor mount 74 with a threaded aperture 76. The sensor is supported by an internally- 16 threaded brass casing which screws into the aperture 76 so that the sensor is in direct thermal contact with the contact plate 64. The heating assembly shown in Figures 2 to 4 may be produced by the following procedure. Firstly a heat distribution plate is induction welded to the underside of the 5 contact plate. Other bonding methods described above may also be used. At this stage, the heat distribution plate need not have a void. A heating element is then bonded to the heat distribution plate. Any one of the bonding methods described above may be used. If the heat distribution plate is not provided with a void, the void is formed by routing or milling away a region of the heat distribution plate to expose the contact plate 10 underneath. The ease of manufacture is improved by forming the void after the heat distribution plate is bonded to the contact plate. The sensor is then mounted in the void in direct thermal communication with the exposed contact plate. Finally the controller is produced and mounted to the heat distribution plate. The heater assembly shown in Figures 14 to 16 may be produced using a similar 15 process. In this case, a toroidal void is formed in the heat distribution plate. The centre of the void is used as a sensor mount. A hole in the centre of the sensor mount is formed to allow the sensor to be in direct thermal communication with the contact plate and, optionally, to be in direct contact with the contact plate. The hole is tapped and the sensor is mounted by screwing a threaded sensor casing into the sensor mount. 20 Further embodiments of the invention will now be described with reference to Figures 18 to 22. For clarity of illustration, Figures 18 to 22 are partial schematic views, intended only to depict alternative arrangements of a heat distribution plate 80 (and contact plate 78) having one or more thermally insulating zones for minimising heat transfer between the heat distribution plate 80 and a temperature sensor 82. 25 For ease of illustration the heat distribution plate and thermally-insulating void(s) are shown as rectangular regions. In practice, of course, the regions may be rounded or of any other regular or irregular shape.

17 Figures 18 and 19 respectively provide a plan view and perspective view of one alternative embodiment of the invention. In this embodiment the heat distribution plate 80 is provided with a plurality of ribs 86, which abut the sensor support 84. As can be most easily seen in the perspective view of figure 19, the thermally insulating zone in 5 this embodiment includes a plurality of voids 22 defined by the ribs 86, the heat distribution plate 80, and the sensor support 84. While a small amount of heat from the heat distribution plate 80 will, in use, be transmitted along the ribs 86 to the sensor support 84, the voids 88 provide thermal insulation to the arrangement and serve to limit the amount of heat transfer to the sensor support 84 and temperature sensor 82 from 10 the heat distribution plate 80. In the embodiment of figures 18 and 19 four ribs 86 have been shown, however more or fewer ribs may be provided as desired. The heat distribution plate 80 may be integrally formed (e.g. by casting) with ribs 86 and/or the sensor support 84. Alternatively, the heat distribution plate 80 may be provided with a region (either during manufacture of 15 the heat distribution plate 80 or by milling/ routing as described above) in which the ribs 86 and sensor support 84 may be positioned and secured. Figures 20 and 21 provide side and perspective views of a further alternative embodiment. In this case the thermally-insulating zone in the heat distribution plate is provided by a void region 90 in the heat distribution plate 80 that does not extend the 20 full depth of the heat insulation plate 80. In this arrangement a thin section 92 of the heat insulation plate 80 remains between the void region 90 and the contact plate 78. This arrangement may be manufactured, for example, by milling or routing void region 90 out of the heat distribution plate 80 as described above, but only to a depth such that section 92 remains. 25 The sensor support 84 may be part of the heat distribution plate 80 that remains after the void region 90 has been removed. Alternatively, the sensor support 84 may be a separate component positioned in a hole in section 92. As shown in figures 21 and 22, a hole 94 may then be drilled or otherwise formed in section 92 for accommodating the temperature sensor 82 and, if necessary, the sensor 18 support 84. By way of alternative, and as shown in figure 22, the hole 94 may be provided so as to directly support the temperature sensor 82, thereby doing away with the need for a sensor support 84. As with the ribs 86 described above, section 92 will allow some heat transfer from the 5 heat distribution plate 80 to the temperature support 84 and/or temperature sensor 82, the amount of heat transfer dependent on the thickness of section 92. By keeping section 92 thin relative to the depth of the recess 90, however, direct heat transfer from the heat distribution plate 80 to the sensor support 84 and/or temperature sensor 82 is limited. 10 In figures 20 to 22 the thin section 92 is adjacent to the contact plate 78. As an alternative, the thin section may remain at the opposed edge of the heat distribution plate 80, leaving a void between the contact plate 78 and the thin section of the heat distribution plate. The void acts to provide a thermally insulating zone. While in the embodiments described with reference to figures 19 to 22 the temperature 15 sensor 82 is shown as being located in the thermally insulating zone by securement (either directly or via the sensor support 84) to the heat distribution plate 80, alternative locating arrangements are possible. For example, the temperature sensor 82 (and/or the sensor support 84 should such be being used) may be located in the thermally insulating zone by a bracket or similar (such as bracket 32 described above in relation 20 to figures 2 to 4). Such a bracket could itself be secured to the heat distribution plate 80, or to any other viable support, for example a printed circuit board located adjacent to the heat distribution plate. The support may include a spring or similar means for biasing the sensor against the contact plate. As a further alternative, the temperature sensor 82 (and/or sensor support 84 if such is being used) may be secured directly to and 25 supported by the contact plate 78. This securement may be via an adhesive or other bond. Many alternative embodiments of the present invention are possible without departing from the principles of the present invention. For. instance, the void may have any number of different shapes. Likewise, there can be a small portion of thermally 19 conductive material (such as the brass casing) between the contact plate 64 and the sensor 70. Further, the heat distribution plate does not need to be in direct contact with the contact plate and the heating element does not need to be in direct contact with the heat distribution plate, so long as these components are in thermal communication with 5 each other. The principles of the present invention may be applied to other types of heating vessels, such as percolators, mocha makers, rice cookers, slow cookers and electric fry ware. It will also be understood that the invention may be applied to kettles having a different configuration to that shown in figure 1, for example a cordless kettle having a base and 10 a removable vessel. In each case, the appliance has an electronic sensor which is insulated from a heating element by a thermally insulating zone and is in thermal contact (and possibly direct contact) with a contact plate. In the case of fry ware, the heating chamber is the pan. It will be understood that the invention disclosed and defined in this specification 15 extends to all alternative combinations of two or more of the individual features mentioned or evident from the text or drawings. All of these different combinations constitute various alternative aspects of the invention. The term "comprises" (or its grammatical variants) is used in this specification as equivalent to the term "includes" and neither term should be taken as excluding the 20 presence of other elements or features.

Claims (3)

1. A kettle for heating water located in a heating chamber of the kettle, the kettle including: (a) a contact plate defining a base of the heating chamber and having a contact 5 surface that, in use, is in direct thermal communication with the water located in the heating chamber of the kettle; (b) a heat distribution plate in thermal communication with and welded to the contact plate, wherein the heat distribution plate is thicker than the contact plate and has a thermal conductivity that is higher than a thermal conductivity of the 10 contact plate, the heat distribution plate defining at least one void that provides a thermally-insulating zone surrounded by the heat distribution plate; (c) a curved resistive heating element ending in a pair of cold tails, the heating element welded to a peripheral region of the heat distribution plate in thermal communication with the heat distribution plate; 15 (d) an electronic temperature sensor located within the thermally insulating zone in thermal communication with the contact plate, the electronic temperature sensor being thermally insulated from the heat distribution plate by the thermally insulating zone, the electronic temperature sensor sensing temperature in a continuous range; 20 (e) a controller for controlling the heating element; and (f) a button arrangement in communication with the controller for a user to select between different heating modes of the controller, wherein the controller controls the heating element responsive to the temperature sensed by the electronic temperature sensor and the controller activates the different heating modes 25 dependent on a selection made using the button arrangement, wherein the heat distribution plate is provided with a plurality of ribs and the thermally insulating zone includes a plurality of voids defined by the heat distribution plate and said ribs. 1001283740 21

2. A kettle for heating water located in a heating chamber of the kettle, the kettle including: (a) a contact plate defining a base of the heating chamber and having a contact surface that, in use, is in direct thermal communication with the water located in 5 the heating chamber of the kettle; (b) a heat distribution plate in thermal communication with and welded to the contact plate, wherein the heat distribution plate is thicker than the contact plate and has a thermal conductivity that is higher than a thermal conductivity of the contact plate, the heat distribution plate defining at least one void that provides a 10 thermally-insulating zone surrounded by the heat distribution plate; (c) a curved resistive heating element ending in a pair of cold tails, the heating element welded to a peripheral region of the heat distribution plate in thermal communication with the heat distribution plate; (d) an electronic temperature sensor located within the thermally insulating zone 15 in thermal communication with the contact plate, the electronic temperature sensor being thermally insulated from the heat distribution plate by the thermally insulating zone, the electronic temperature sensor sensing temperature in a continuous range; (e) a controller for controlling the heating element; and 20 (f) a button arrangement in communication with the controller for a user to select between different heating modes of the controller, wherein the controller controls the heating element responsive to the temperature sensed by the electronic temperature sensor and the controller activates the different heating modes dependent on a selection made using the button arrangement, 25 wherein the at least one void is defined by a portion of the heat distribution plate having a reduced thickness relative to a thickness of a region of the heat distribution plate adjacent to said portion. 1001283740 22

3. A kettle as claimed in claim 2, wherein said portion having reduced thickness is adjacent said contact plate. 1001283740