GB2516053A

GB2516053A - Electrical appliances and components

Info

Publication number: GB2516053A
Application number: GB201312323A
Authority: GB
Inventors: Antonio Martin Gaeta; Simon M Whiteley; Richard Chee Cheung So; Paul Boundy; Andrew Hunt; Robert Henry Hadfield; Trevor Neill Orritt
Original assignee: Otter Controls Ltd
Current assignee: Otter Controls Ltd
Priority date: 2013-07-09
Filing date: 2013-07-09
Publication date: 2015-01-14
Anticipated expiration: 2033-07-09
Also published as: WO2015004451A1; CN204067692U; GB201312323D0; GB2516053B

Abstract

A waterproof electrical plug 3a for a cordless appliance has a main body 22 and a plurality of electrical conductors. At least one seal assembly 385 is provided to seal over and/or around an intermediate portion between the terminal and contact ends of at least one conductor, and the main body is moulded partially or fully over and/or around at least the intermediate portion. This allows a resilient material to give a good seal but firmly holds the conductors in the body. The seal may be moulded in place or may be moulded first and then positioned on the conductors. Ribs (387, Fig 7) may hold multiple seals together to be positioned on the conductors simultaneously. Alternatively the seal may be added after the moulding.

Description

Electrical Appliances and Components

Field of the Invention

[0001] The present invention relates to electrical appliances and components therefor, and particularly, although not exclusively, to cordless domestic appliances.

Background of the Invention

[0002] In a cordless appliance, the appliance proper includes a cordless connector that is operable to cooperate with a corresponding cordless connector on a power base. Thus, when the appliance proper is mounted on the power base, power may be supplied to the applhmce proper. Such arrangements a'low a power base to be connected to a domestic power supply (such as by a plug), whilst further allowing the appliance proper to be removed from the base for various operations, such as dispensing heated liquid from a corWess liquid heating appliance. The above types of cordless electrical connectors have also found use on other domestic appliances, such as food processors, blenders and the like. This arrangement provides an advantage that the processed/blended food can be more easily dispensed by a user.

[0003] 360° cordless connectors, as described for example in the applicant's patent publication WO-Al-94/06185, allow the appliance proper to be rotated freely relative to the power base, so that the appfiance proper may be positioned on the power base with any azimuthal orientation.

[0004] However, as will be appreciated, appliances such as food processors, blenders and, to a lesser extent kettle jugs, need regular cleaning. In particular, cordless appliances for containing food or liquids other than water, for example milk frothers, may require cleaning after each use. Such a task is time consuming and may be difficult to perform manually.

[0005] In the case of cordless appliances, it would be desirable that the detachable part of the appliance can be washed in a dishwasher, by immersion in water or otherwise easily cleaned. Sealing arrangements for such a washproof appliance are disclosed in the applicant's patent publications WO-A1-2008/0l2506 and WO-A1-2009/l09762.

[0006] In addition, there is a constant commercial pressure in the domestic appliance industry to lower the price or reduce the costs of small domestic appliances.

[0007] However, the applicant understands that the issue is greater than just the cost of the materials or components and has realised that there is a need to reduce the impact or cost of domestic appliances through interrelated factors, including 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 manufacturing and assembly, whereby innovation can make great strides in reducing costs. To achieve a reduction in material costs it is necessary to challenge the established prior art methods and ideology.

[0008] One method to reduce the costs of an appliance is to optimise the material usage of the cordless connector, whilst still maintaining the connector's ability to be waterproof such that the appliance may be washed in a dishwasher or by immersion in water.

[0009] It is also preferable that the cordless connector should encompass the need to provide ancillary conductors and signa'ling means, for examp'e, for appliances in which the user controls are in the power base.

Statements of the Invention

[0010] According to a first aspect of the present invention, there is provided a waterproof cordless electrical plug connector for a cordless electrical appliance, the plug connector comprising a main body having a plurality of electrical conductor assemblies, at least one of which comprises at least: a) a proximal end for electrical connection to a socket conductor of a corresponding socket connector; b) a distal end for electrical connection to at least one electrical component of the cordless electrical appliance; and c) an intermediate portion disposed between the proximal end and the distal end, wherein at least one seal assembly is provided to seal over and/or around a sealing area of said intermediate portion, and the main body is moulded partially or fully over and/or around at least the intermediate portion.

[0011] The main body may be moulded partially or fully over and/or around at least said one or more seal assemNy. Alternativdy, at least said one or more seat assemNy may be moulded partially or fully against, over and/or around the main body.

[0012] According to another aspect of the present invention, there is provided a method of assembling a waterproof cordless electrical plug connector for a cordless electrical appliance comprising the following steps: a) providing a plurality of electrical conductor assemblies, at least one of which comprises a proximal end for electrical connection to a socket conductor of a conesponding socket connector, a distal end for electrical connection to an electrical component of the cordless electrical appliance and an intermediate portion disposed therebetween; b) providing at least one seal assembly to seal over andlor around a sealing area of said intermediate portion; c) moulding a main body partially or fully over and/or around at least said one or more seal assembly and the intermediate portion.

[0013] According to another aspect of the present invention, there is provided a method of assembling a waterproof cordless electrical plug connector for a cordless electrical appliance comprising the following steps: a) providing a plurality of electrical conductor assemblies, at least one of which comprises a proximal end for electrical connection to a socket conductor of a corresponding socket connector, a distal end for electrical connection to an electrical component of the cordless electrical appliance and an intermediate portion disposed therebetween; b) moulding a main body partially or fully over and/or around at least the intermediate portion; and c) providing at least one seal assembly to seal over andlor around a sealing area of said intermediate portion and to seal partially or fully against, over and/or around the main body.

[0014] The at east one seal assembly and the main body may be provided as part of a multiple stage moulding process. The multiple stage moulding process may be a two-stage moulding process. Alternatively, the at least one seal assembly and the main body may be provided as part of a single stage moulding process, such as a twin-shot moulding process.

[0015] Embodiments of the invention cover a series of disclosures which include: a) Arrangements to reduce the cost of associated components within the appliance.

b) Arrangements to reduce the costs of the associated appliance.

Brief Description of the Drawings

[0016] 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 2 illustrates an isometric view of the applicant's culTent CP8 TM washproof plug connector.

Figure 3 illustrates an isometric view of a reduced size washproof cordless connector according to an embodiment of the present invention from above.

Figure 4 illustrates an isometric view of the reduced size washproof cordless connector of Figure 3 from below.

Figure 5 illustrates an exploded view of conductor assemblies.

Figure 6 illustrates an exploded view of the conductor assemblies assembled in position and a seal.

Figure 7 illustrates a detailed view of the seal of Figure 6.

Figure 8 illustrates a cross section along line A -A of the seal of Figure 7.

Figure 9a illustrates an isometric view of the seal secured to the conductor assemblies.

Figure 9b illustrates a detafled view of the tab terminals on the reduced size washproof cordless connector.

Figure 9c illustrates a detailed view of an alternative alTangement to that of Figure 9b.

Figure 10 illustrates an exploded view of the reduced size washproof cordless connector of Figure 3 with a resilient seal and the applicant's CS8 TM cordless socket connector.

Figure 11 illustrates a schematic cross section of the reduced size washproof cordless connector of Figure 10 secured and sealed within the appliance.

Figure 12 illustrates a plan view of the seal secured to the conductor assemblies.

Figure 13a illustrates a second variant of the seal of Figure 7.

Figure 13b illustrates a third variant of the seal of Figure 7.

Figure 1 3c illustrates a douNe sealing arrangement in an altemative embodiment.

Figure 1 3d illustrates a cross section along line A -A of the double sealing arrangement of Figure 1 3c.

Figure 13e illustrates a variant of the double sealing arrangement of Figure 13d.

S

Figure 14 illustrates an isometric view of an alternative embodiment of the reduced size washproof cordless connector to that of Figure 3.

Figure 15 illustrates a cross section along line B -B of the reduced size washproof cordless connector of Figure 14.

Figure 16 illustrates an isometric view of a variant of the reduced size washproof cordless connector of Figures 14 and 15.

Figure 17 is a plan of the conductors and seal according to a further embodiment to that of Figure 3.

Figure 18 is a plan of a sub assembly of conductors and the seal prior to a second over-moulding process according to the embodiment of Figure 17.

Figure 19 is an isometric view of the assembled reduced size washproofcorWess connector according to the embodiment of Figure 17.

Figure 20 illustrates a plan view of an alternative arrangement of the conductor assemblies.

Figure 21a illustrates an exploded isometric view of a further embodiment of the reduced size washproof cordless connector and the seal.

Figure 21b illustrates an assembled isometric view the reduced size washproof cordless connector and the seal of Figure 21a.

Figure 22 illustrates a schematic cross section of another embodiment of the reduced size washproof cordless connector secured and sealed within the appliance.

Detailed Description of the Embodiments

[0017] The following description discloses innovations that individually, or in combination may find use in alternative domestic and commercial appliances.

[0018] The embodiments are presented in separate sections of this document and each of these sections will include a brief introduction to the specific problem.

[0019] 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.

[0020] Within the statement of invention, description and claims, the invention may be described as reduced size' which covers the potential to reduce, for example, material usage in comparison to prior art design andlor assembly methods. The term reduced size' is not intended to be limiting.

[0021] 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 [0022] 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 wifi be hereon referred to as the plug.

[0023] 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.

[0024] The following description discloses a combination of measures that may advantageously impact on costs and price in all their aspects.

[0025] 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.

[0026] In the following description the electrical power supply ead 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.

[0027] Within the statement of invention, description and daims, unless otherwise stated, the terms liquid and water are intended to have equivalent meaning.

[0028] Within the statement of invention, description and claims, unless otherwise stated, the terms kettle, appliance, vessel and reservoir may have equivalent meaning [0029] Within the statement of invention, description and claims, unless otherwise stated, the Lerms part and portion are intended to have equivalenL meaning [0030] Within the statement of invention, description and claims, unless otherwise stated, the terms waterproof. wash proof and immersable in water are intended have equivalent meaning.

[0031] Within the statement of invention, description and daims, unless otherwise stated, when describing electncal connections the terms discrete contact, contact portion and contact area are intended to have equivalent meaning.

[0032] 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.

[0033] Within the statement of invention, description and daims, unless otherwise stated, when describing one part of a vessel body the terms opening and aperture are intended to have equivalent meaning.

[0034] Within the statement of invention, description and daims, unless otherwise stated, when describing the tnp lever andlor control the terms over centre and bistable are intended to have equivalent meaning.

[0035] 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 I and a power base 2 having respective body and base cordless connectors 3 and 4, such as 3600 cordless connectors of the type described in the applicant's own patent publication WO-A1-94/06 185 and/or as sold by Otter Controls Ltd under, for example, the CS4/CS7 TM Senes (power base socket) and the Al TM, CP7 or CP8 TM (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 I and/or base 2 and/or cordless connector 3 and/or cordless connector 4 may be provided with emitters and/or detectors 3l, annular seals 21 which may be optically transmissive andlor annular optically transmissive nngs 41.

[0036] The jug kettle may include an electro mechanical control 60, for example the applicant's own Al series integrated 3600 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 Ihe appliance. Alternatively an electronic control IS may employ an alternative user interface 11. Either or both of the electronic control 15 andlor user interface 11 may be situated in one or both of the vessel I and/or base 2.

[0037] The vessel body I comprises a reservoir 5 for containing liquid to be heated, lid 8, spout 7, handle 9 and a base section or compartment 6 having a sub-base portion 19, which forms the bottom surface of the vessel body 1. The spout 7 may provide pnmary venting and/or pressure equalisation. The spout 7 may further include a spout filter 740 having a screen mesh 659. The vessel body I may be further provided with a baffle 730 located behind the spout 7, as described in the applicant's own patent publication GB-A-248457l, for reducing or inhibiting water from being ejected or spitting out of the spout during the heating process.

[00381 The connector 3 may be a waterproof or washproof connector 3 sealed into the appliance 1 directly andlor indirectly via the sub base 19 with seals 21, and so provide a sealed area and/or compartment 6 within the appliance I in which electrical components. for example heating elements, mechanical or electronic controls, NTC, stirrer, mixer, blender, sensor, residual current protector, motor, chargeable or non-chargeable power supply, lift-off switch-off mechanism, wiring harnesses etc, may be housed, thus allowing the appliance to be washed in a dishwasher or cleaned by immersion in water, as described in the applicant's own patent publication WO-A 1-2008/012506.

[0039] 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 8 may be securably sealed to the vessel so that the lid 8 remains in place and does not leak liquid in the case that the appliance is tipped over. The lid 8 may further include a spill inhibiting means 149, as described in the applicant's own patent publication WO-A2-2011/101642 to reduce or eliminate spillage if the appliance is accidentally tipped or knocked over.

[0040] 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 I 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.

[0041] Liquid is healed by an element plale i2 which may lorm the base of the reservoirS.

The reservoir 5 of the appliance 1 may be provided with water level markings andlor other features that indicate the state of the appliance I. 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 andlor 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 maybe supported in the vessel I 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.

[0042] 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.

[0043] 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.

[0044] 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 Washproof Cordless Plug Connector [0045] In cordless electrical washproof appliances, for example, blenders, mixers and frothers, it is preferable that the appliance proper is able to be washed in a dishwasher or immersed in water after use. Generally, in the case of cordless electrical appliances the appliance proper 1 includes a cordless plug 3 and the cordless power base 2 includes a cooperating cordless socket 4 for providing power to the appliance 1. There is generally no necessity to immerse the cordless power base 2 into water for cleaning, in which case this application will concentrate on the waterproofing of the appliance I. The applicant's CP8 washproof electrical connector, as disclosed in the applicant's patent publication WO-Al- 2008/012506, provides a workable solution to the problem of sealing conductors into the cordless plug 3. Furthermore, the applicant's patent publications provide solu6ons for sealing the plug connector 3 into the appliance 1, for example as disclosed in WO-Al-2008/012506 and so provide a sealed area andlor compartment within the appliance in which electrical components for example heating elements, mechanical or electronic controls, wiring harnesses etc may be housed.

[0046] Figure 2 illustrates the applicant's culTent production version of CP8TM series washproof connectors 3, whereby the electrical connections 507L, 507N, 507E (on the dry side of the cordless connector 3) are each provided with cavities 526 that are defined by the walls 522.

[0047] The electncal connections 507L, 507N are formed as part of contact plates positioned at the bottom of the cavity 526. The contact plates are connected via a weld or other means to the live and neutral conductors which pass through the bottom of the cavity 526 from the wet side of the connector 3.

[0048] The earth tab terminal 507E is provided on the distal end of earth terminal 127, which is connected directly to the top of the central earth pin 525 and passes through the bottom of the cavity 526 into the wet side of the connector 3.

[0049] The cavities 526 are then filled with a sealing means 523, for example silicone, so that liquid cannot pass from the wet side to the dry side.

[0050] The arrangement of the CP8 IM series also provides sufficient creepage between the conductors 507L, 507N, 507E on both the dry side and the wet side so as to prevent electrical arcing or tracking between the conductors. This is particularly important on the dry side, in the case that small amounts of conductive liquid have leaked into the sealed compartment 6. To achieve this, the conductors are spaced apart by a sufficient distance and the materials for the sealant and plastic moulding have a suitable Comparative Tracking Index (ICTI).

[0051] The CP8 TM series is designed to interface with the applicant's cooperating CS7 TM cordless sockets (not shown).

[0052] The prior art washproof connector 3 functions admirably to prevent water entering the appliance through the connector 3. however the assembly methods, for example the application of the sealant, are difficult to automate and, in the case of liquid sealant, time is required for the sealant to cure. Furthermore, the sealant fills the cavity under gravity, in which case suilicieni space is required around each conductor For the sealant to how, which in turn increases the width and height of the cavity and impacts both on the amount of sealant used and the height and size of the connector 3.

[0053] The applicant's patent publication WO-A 1-2008/012506, discloses further methods for sealing the conductors into the connector moulding 22 induding insert moulding.

However, it has been found that engineenng plastics, for example with suitable mechanical strength and electrical insulation properties, may not provide a capable sealing interface with the electrical conductors so that water may seep through the connector 3 along the mating surface between the conductors and the main moulding 22. In particular the different coefficients of expansion between the plastic and conductor may subject the mating sealing faces to movement and compromise the seaL for example when subjected to cooling following the moulding process andior high temperatures and aggressive detergents, as experienced in a dishwasher. Additionally, the increase and decrease of ambient pressure within the sealed compartment may gradually compromise any weak point along the conductor.

[0054] Conversely, more resilient materials suitable for sealing against conductors in a range of temperatures are proportionally more expensive and may not have the required mechanical and/or dectrical integrity for use as a main moulding in an appliance plug connector.

[0055] Therefore there is a need to provide an assembly process in which a specialist sealing portion is provided to seal between the plastic and metal portions whilst also providing the required resilience to accommodate the differential movement between the plastic and metal during assembly and/or in use.

[0056] The following description discloses embodiments of a reduced size washproof cordless connector 3a that provide improvements over the prior art washproof connector 3, in which the connector 3a is assembled in at least two stages. The first stage comprises applying the sealant substantially onto andlor around the conductors and the second stage comprises over-moulding the main moulding 22 substantially over and/or around the conductors and the sealant. As a result, the amount of sealant is minimised and the structural and electrical integrity of the connector 3a is provided by the conductors 394L, 394N, 394E and main moulding 22. Advantageously, the proposed assembly/manufacturing process may be more readily automated, particularly if the sealant does not require a curing time after assembly.

[0057] The following embodiments may include features as described or disclosed with reference 10 the appficani's patenl publications WO-Al-2008/012506 arid CN-U-202695826.

Unless otherwise stated, it is not intended to further describe those features.

[0058] Figure 3 is an isometric view of first embodiment of the reduced sized washproof cordless connector 3a from above. Figure 4 is an isometric view of the reduced size washproof cordless connector 3a of Figure 3 from below.

[0059] Figure 5 illustrates an exploded view of the conductor assemblies 394L, 394N, 394E, and Figure 6 illustrates the conductor assemblies 394L, 394N, 394E assembled in position prior to a seal assembly 385 being attached thereto.

[0060] The reduced material washproof cordless connector 3a may include bosses 282 or other features, such as snap-fittings, click-fits or rivets to allow the reduced material washproof cordless connector 3a to be secured to a sub base.

[0061] For illustrative purposes, the prior art washproof connector 3 of Figure 2 and the embodiment of the reduced size washproof cordless connector 3a of Figure 3 are illustrated with comparable scale to illustrate reduced amount of material used and/or height of the reduced size washproof cordless connector 3a.

[0062] The reduced size washproof cordless connector 3a is illustrated as a 3600 cordless plug 3a to interface with the applicant's CS8 TM cordless socket connector 4, as described in the applicant's patent publication WO-Al-2013/093526. However, the teachings of this application are equally applicable to other arrangements including 3600 and non 360° cordless plugs 3 suitable to cooperate with any proprietary cordless socket connector.

[0063] As illustrated, the cordless plug connector 3a includes three conductors3OL, 534N, 534E, however the teachings are equally applicable to cordless plug connectors with more than or fewer than three conductors as may be required to carry power and/or signals between the appliance I and the cordless power base 2.

[0064] As shown in Figures 3, 4 and 5, the reduced size washproof cordless connector 3a comprises a main moulding 22 and a plurality of electrical conductor assemblies, for example, 394L, 394N, 394E. Each of the electrical conductor assemblies 394L, 394N. 394E may further include: a. a proximal end for electrical connection to a mating socket connector 4, for example, a central conductor 530 andlor annular ring conductor 534; b. distal end for electrical connection to an appliance component. for example, tab terminals 507L. 507N, 507E; c. and an inteimediate portion 539L, 539N, 539E disposed between the proximal end and the distal end that comprises at least one sealing area 390.

[0065] As illustrated the central live conductor assembly 394L includes a central pin 530L, and the neutral and earth conductor assemblies 394N, and 394E comprise annular ring conductors 534N and 534E respectively. The intermediate portion 539 may be a lateral part (as shown in Figures 5 and 6) that may act to position and assist in securing the conductor assemblies 394L, 394N, 394E within the main moulding 22 during assembly. Other connection means 507 including rivets, planished portions or crimps may be provided on the distal ends of the conductor assemblies 394. As illusftated, each of the proximal, intermediate and distal portions of the conductor assemblies 394L, 394N, 394E may be fixed and/or rigid.

In alternative embodiments, at least one portion of the conductor assemblies 394L, 394N, 394E may be resilient and, for example, may form a movable spring contact which may form part of an electrical switch.

[00661 The conductor assemblies 394L, 394N, 394E may be stamped, folded and formed from a flat and/or strip material such as brass and/or copper alloy and may be plated and/or provided with low resistivity material such as silver, as described in the applicant's patent publication WO-Al-2013/093526. In alternative embodiments, each of the conductors 394 can be assembled from discrete parts, for example, as illustrated the pin 530L may be mechanically connected to the intermediate portion 539L.

[0067] As illustrated in Figure 4. the main moulding 22 comprises an aperture 393 for housing the three fixed conductors 534E, 534N and 530L for interfacing with, for example, the appficant's CS8 cordless socket connector 4, as described in the applicant's patent publication WO-AI-2013/093526.

[0068] Figure 7 illustrates a detailed isometric view of the seal assembly 385 of Figure 6, and Figure 8 illustrates a cross section of a discrete seal portion 386 in position with the conductor 394.

[0069] Figure 9a illustrates an isometric view of the reduced size connector 3a including the seal 385 prior to the over-moulding of the main mould 22 and Figures 9b and 9c illustrate variants of the assembly after the over-moulding process.

[0070] The seal assembly 385 may comprise a series of discrete seals 386 that be may be further provided with interconnecting ribs 387. The interconnecting ribs 387 may assist in securing the seals 386 and/or conductor assemblies 394L, 394N. 394E during or prior to assembly and/or assisi with Ihe flow of sealing malerial during the moulding process. The ribs 387 may be removed pnor to the over-moulding stage of the assembly.

[0071] The seal assembly 385 may be moulded directly substantially onto and/or around the conductor assemblies 394L, 394N, 394E, for example, in an injection mou'ding process.

Alternatively, the seal assembly 385 may be pre-formed and positioned over and/or around the conductor assemblies 394L, 394N, 394E. It can be envisaged that, for example, the seal material is elastic and/or resilient and the aperture(s) 414 in the preformed seal assembly 385 may be smaller than the cross-section of the conductor assemblies 394L, 394N, 394E so that the seal 385 may be stretched over the conductor assemblies 394L, 394N, 394E.

Advantageously, the effect of the undersized pre-formed seal 385 stretched around the conductor may provide an additional compression force to enhance the sealing means.

[00721 As illustrated, the conductor assemblies 394L, 394N, 394E are alTanged concentncally and may be held in position by a jig (not shown) during the assembly/mou'ding process to allow the seal 385 to be mo&ded and/or positioned around, for example, the sealing area 390 of each conductor assembly 394L, 394N, 394E. The conductor assemblies 394L, 394N, 394E may be provided with an aperture 414 or recess 389 in the sealing area 390 such that the seal 385 can be positively secured and/or anchored to the conductor assemblies 394L. 394N, 394E during the assemNy and/or moulding process. The seal 385 may include cooperating retention features to further secure the seal 385 to the conductor assemblies 394L, 394N, 394E. For example, as illustrated in Figure 8, the aperture 414 of the conductor 394 may be filled with the sealant 385 during the moulding process to form anchoring means 391 to allow the seal 385 to be positively secured and/or anchored to the conductor assemblies 394L. 394N, 394E.

[0073] Alternatively, the sealing area 390 may be provided with a textured, roughened and/or etched surface (not shown) to further improve the adhesion and or sealing means between the seal 385 and the conductor assemblies 394L. 394N. 394E. It is also preferred that any sharp edges formed during the stamping of the conductor assembly 394L, 394N, 394E are removed by a secondary operation.

[0074] The periphery of the seal 385 may be provided with a profile 388 to allow the seal 385 to be positively secured and/or anchored to the main moulding 22 during the over-moulding process. In an alternative embodiment (not shown), the profile 388 may be omitted.

[0075] The seal 385 may be made from an elastomeric material or from a resilient polymeric material, such as a polymer, polyarnide, copolyaniide and/or copolymer etc. The main moulding 22 may be made from a rigid and/or engineered plaslic rnaieriál such as polybutylene terephthalate, reinforced polybutylene terephthalate andlor polypropylene etc, and so act as a mechanical support for the assembly.

[0076] The properties of the seal allow the seal 385 to function as a primary seal between the conductor assemblies 394L. 394N. 394E and the main mould 22, and may also provide resilience andlor flexibility therebetween.

[0077] Whereas it is understood that moulding the main mould 22 directly onto a conductor 394 may cause problems when the main mould 22 shrinks as it cools, however it can be envisaged that the shrinkage of the main moulding 22 may further compress/clamp the seal 385 between the main mould 22 and conductor assemblies 394L, 394N, 394E and so improve the sealing means.

[0078] As illustrated in Figures 9b, the over-moulding of the main mould 22 may completely cover the seal 385 on the dry side of the connector 3a. Alternatively, as illustrated in Figure 9c the shut off point of the mould 22 may finish level with or short of the end face of the seal 386 so that at least the end of the seal 386 may be exposed, which may further allow for flexing due to, for example. the differential expansion between the seal 385 and the conductor assemblies 394L, 394N. 394E and/or the seal 385 and the main moulding 22. In the case that the seal 386 is not suitable and/or approved for exposure in electrical appliances, a separate sleeve, cover, plug and/or cap may be applied over the seal 386. Alternatively, a coating may be applied over the seal 386.

[0079] The combination of the seal 385 and the over-moulding 22 provides a discrete sealing portion 386 around each conductor assembly 394L, 394N, 394E. so that each conductor assembly 394L, 394N, 394E is at least partially embedded within the sealing portion 386. and the sealing portion 386 is at least partially embedded within the main moulding 22, so preventing liquid travelling from the wet side of the connector 3a along the conductor assemblies 394L, 394N, 394E and through the main moulding 22 into the dry side of the appliance 1.

[0080] Figure 10 illustrates an exploded view of an embodiment of the reduced size connector 3a with a resilient seal 21 for sealing the connector 3a into, for example, the sub base of the appliance I. The resilient seal 21 has two sealing surfaces, as described in the applicant's patent publications WO-Ai-2008/0i2506 and CN-U-202695826. Figure 11 illustrates a schematic cross section of the connector 3a installed/sealed within the sub base 19, in which the first sealing surface may comprise at least one radially outwardly extending circumferential fin 23 located between upper/lower ends 28 of the resilient seal 21, which may deform to take the shape of the sealing face of the sub base. The second sealing surface may comprise at least one radially inward extending circumferential rib 27 for sealing against the sealing face of the cordless connector 3a and so maintaining a waterproof electrical connector means for the compartment 6 formed, for example, by the sub base 19.

[0081] Figure 10 also illustrates the applicant's CS8 TM cordless socket connector 4, as described in the applicant's patent publication WO-Al-20l3/093526, for interfacing with the reduced size washproof cordless plug connector 3a. It is not intended to further describe the features of the applicant's CS8 cordless socket connector 4.

[0082] Figure 12 illustrates a plan view of the seal 385 secured onto and/or around the conductor assemblies 394L, 394N, 394E. As illustrated, a minimal Distance A may be required between adjacent terminals 507L, 507N, 50Th to provide suitable electrical clearances. As illustrated in plan view, the conductor assembly 394L, 394N, 394E may be substantially narrower at the sealing area 390, which may increase the creepage distance between the sealed conductors to make provisions against small of amounts of conductive liquids that may have leaked into the sealed compartment 6. Suitable clearances and creepage distance are chosen according to CTI of the materials and the voltage, current and/or power rating of the application.

[0083] As previously described prior to the over-moulding, the interconnecting portions 387 may be removed, however this may be considered wasteful of the expensive sealant material. Alternatively, as illustrated in Figure 13a. to control wastage the seal 385a may comprise a series of discrete sealing portions 386 for the individual sealing areas 390 of the conductor assemblies 394L. 394N, 394E. The discrete seals 386 may be provided as pre-moulded components and then assemNed onto the conductor assemblies 394L, 394N, 394E or moulded directly onto or over the conductor assemblies 394L, 394N, 394E as previously described. With the interconnecting rib 387 removed, it can be envisaged that during the second stage over-moulding process the gap between the adjacent seals 386 may be filled by the material of the main mould 22. Advantageously, this minimises the risk of water passing/seeping between the conductor assemblies 394L, 394N, 394E within the main mould [0084] Figure 13b illustrates a third variant of the seal 385. whereby the seal 385b is a single elongated seal which may simphly the moukl looling and subsequeni moulding process.

[0085] Figure 13c illustrates a double sealing arrangement 385c, whereby at least two seals, for example. a primary seal 385i and a secondary seal 385ii. may be provided in tandem to provide greater redundancy or factor of safety should the integrity of the primary seal 385i fail. Figure 13d illustrates a cross section through the double sealing arrangement 385c in which a gap may be provided between the adjacent seals 385, which will be tilled during the second stage over-moulding process to support the seals 385i and 385ii in use.

[0086] Figure 13e illustrates a variant of the double sealing arrangement 385d, whereby the seals 385e may have a reduced width to provide additional material saving, whilst still able to offer the greater redundancy or factor of safety of the double sealing arrangement 385c of Figure l3d.

[0087] Figure 14 illustrates an embodiment of the reduced size washproof cordless connector 3b, whereby the main moulding 22 may be provided with at least one housing 32 for receiving an optical transmitter 31 such as an LED for transmitting data from the appliance to an optical receiver on the cordless socket connector of the cordless power base (not shown) to provide a one-way communication link, which will be described in more detail below.

[0088] Figure 15 illustrates a section through line B-B of the reduced size washproof cordless connector 3b of Figure 14, whereby signals from the optical transmitter 31 are transmitted to the optical receiver on the cordless socket connector of the cordless power base (not shown) via the optically transmissive seal 21 as described in the applicant's patent publications WO-A2-2011/i0i642 and CN-U-202695826. and solutions for providing signalling from the appliance proper I to the cordless power base 2, for example as disclosed in WO-A2-201 1/101642 [0089] Figure 16 illustrates a variant of the reduced size washproof cordless connector 3c of Figures 14 and 15. whereby the main moulding 22 may be provided with at least one housing 32 for receiving said optical transmitter 31 and at least one further housing 32a for receiving an optical receiver, such that signals may be transmitted between the appliance and the cordless socket connector on the cordless power base (not shown) to provide a two-way communication link.

[0090] Alternatively, the optical receiver may be directly housed and/or mounted to the cordless power base.

[0091] Figures 17 to 19 illustrate a further embodiment of the reduced size washproof cordless connector 3d, whereby lateral conductors 539N. 539L, 539E may be stamped and/or cropped from a continuous strip of material 391, whereby the lateral conductors are supported by a carrier 392. The lateral conductors. .39N, 539L. 539E may be provided with location apertures 4l4a to enable conductor rings 534N, 534E andlor pin 530L (shown in dotted lines) to be secured thereto either prior to or after the assembly process or moulding stages.

[0092] After the stamping andlor cropping process, the sealant 385 may be substantially applied onto andlor around the sealing area 390 of the lateral conductors 539N, 539L, 539E.

The second stage over-moulding process may then proceed and so form the connector moulding 22 around the conductor assemblies 394L, 394N, 394E and the sealant 385.

[0093] In further embodiments (not shown), the reduced size washproof cordless connector may further compnse at least an appliance control a steam control or a thermal control. The appliance control, steam control or thermal control may be integrated with the reduced size washproof cordless connector.

[0094] As illustrated in Figures 3 to 19, the terminals 507 of the conductor assemblies 394 radiate outwardly and substantially terminate in a parallel formation so that the discrete sealing means 396 may be arranged substantially side-by-side or linearly. However, as illustrated in Figure 20 at least one of the conductor assemblies 394 may radiate at an angle, for example substantially 180°, from at least one other conductor 394. In further embodiments (not shown), each of the conductors may radiate at different angles to suit specific application requirements. In still further embodiments at least one of the connections 507 may be angled, for example upwards, to suit specific application requirements.

[0095] In further embodiments, a single conductor wire may be attached, by for example welding, to at least one connector/terminal 507 prior to the over moulding stage. The connector/terminal 507 and at least pail of the wire may then be over-moulded. The over-moulding may be part of an over-moulded seal andior main moulding 22, or may be a discrete portion over-moulded in a separate process. Alternatively, a sheath or heat shrinkable sleeve may be applied over the connector/terminal 507 and at east part of the wire.

[0096] Whilst the description so far has disclosed a multi-stage assembly, in which the first stage is applying the sealant 385 substantially onto andior around the conductor assemblies 394 and the second stage over-moulding the main moulding 22 substantially over and/or around the conductor assemblies 394 and the sealant 385, it can be envisaged that in furiher embodiments Ihe main moulding 22 may be applied first and Ihe sealant 385 may be applied in the second stage.

[0097] Figures 21a and 21b illustrate an embodiment, in which the main moulding 22 is applied over the conductor assemblies 394 at the first stage and the seal 385 is then moulded as the second stage. As illustrated, the main mould 22 may include features 388 to act as retention features for an over-moulded seal 385. Alternatively or additionally, the main moulding 22 may include an aperture 395 which may be partially or fully filled by the sealant 385 during the second moulding process.

[0098] As illustrated, the sealing area 390 may be provided with aperture 414, recess 389 and/or textured. roughened and/or etched surface 395 to allow the seal 385 to be secured, anchored and/or adhered to the sealing area 390 of the conductor assemblies 394.

[0099] In further embodiments, there may be three stages with, for example, the primary seal 385 being applied at the first stage, the main moulding as the second stage and a secondary seal in the third stage. Each of the seals may be moulded and/or provided as pre-formed components, so that for example, the secondary seal may be pre-formed cover, cap or plug and secured to and/or over at least the main moulding and a portion of the conductor assemblies.

[00100] In further embodiments and/or in addition to the previously described embodiments, at least one seal 385 may be applied within and between the conductors 530 and 534 as illustrated in Figure 22.

[00101] In further embodiments both the seal assembly 385 and the main moulding 22 may be appfied in a single stage process, for example. in a twin shot moulding process.

[00102] Whilst the figures and description may disclose specific orientation and/or polarity of the conductors and size and type of seal and main moulding, it can be envisaged that the orientation and/or polarity of the conductors and size and type of seal and main moulding may change without departing from the scope of the invention.

[00103] It can be envisaged that the appliance proper may comprise at least one sealed user actuable switch as disclosed in the applicant's patent publication GB-B-2482497.

Alternatively, the appliance proper may comprise at least one touch sensitive switch, for example, a capacitive, resistive and/or piezo touch switch, for operating various functions of the appliance proper. The touch sensitive switch may be provided on the entire or on a portion of the appliance body. As a result, the touch sensitive switch may not require addilional mounting aperture(s) made in the appliance body nor additional sealing.

Alternatively, the appliance switch and/or touch sensitive switch may be located on the power base.

[00104] It can be envisaged that a base component of the appliance, as disclosed in the applicant's patent publication WO-Al-2008/012506, may comprise the previously described reduced size washproof cordless connector, in which case the base component may be seal to and/or removably secured or secured to the appliance.

Alternative Embodiments [001051 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 tnmsfer solutions between the embodiments to meet the specific problems of individual appliances within the scope of the present invention.

[00106] 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.

Claims

CLAIMS: I. A waterproof cordless electrical plug connector for a cordless electrical appliance, the plug connector comprising a main body having a plurality of electrical conductor assemblies, at least one of which comprises at least: a. a proximal end for electrical connection to a socket conductor of a corresponding socket connector; b. a distal end for electrical connection to at least one electrical component of the cordless electrical appliance; and c. an intermediate portion disposed between the proximal end and the distal end, wherein at least one seal assembly is provided to seal over and/or around a sealing area of said intermediate portion. and the main body is moulded partially or fully over and/or around at least the intermediate portion.
2. The waterproof cordless electrical plug connector of claim i, wherein the main body is moulded partially or fully over and/or around at least said one or more seal assembly.
3. The waterproof cordless electrical plug connector of claim 1, wherein at least said one or more seal assembly is moulded partially or fully against, over and/or around the main body.
4. The waterproof cordless electrical plug connector of any one of claims 1 to 3, wherein the at least one seal assembly provides resilience to accommodate the differential movement between the main body and each electrical conductor assembly during assembly and/or in use.
5. The waterproof cordless electrical plug connector of claim 1 or 4, wherein the at least one seal assembly is made from an elastomeric material or from a resilient polymeric material, such as polymers, polyamides, copolyamides and/or copolymers etc.
6. The waterproof cordless electrical plug connector of any one of claims I to 5, wherein the sealing area of said intermediate portion comprises means for retaining the at least one seal assembly, the means preferably comprising at least a recess, aperture, textured surface, roughened surface and/or etched surface to allow the at least one seal assembly to be positively secured, anchored and/or adhered to the sealing area.
7. The waterproof cordless electrical plug connector of any one of claims I to 6, wherein the at least one seal assembly is directly moulded over and/or around the sealing area of said intermediate portion.
8. The waterproof cordless electncal plug connector of any one of claims 1 to 6, wherein the at least one seal assembly is a pre-formed seal positioned over and/or around the sealing area of said intermediate portion
9. The waterproof cordless electrical plug connector of claim 8, wherein the at least one seal assembly is a pre-formed elastic and/or resilient seal comprising a reduced cross section relative to the sealing area, such that the pre-formed elastic and/or resilient seal is stretched over the sealing area of the intermediate portion to provide an additional compression force to enhance the sealing interface over the sealing area.
10. The waterproof cordless electrical plug connector of any one of claims I to 9,herein the main body is made from a rigid and/or engineered plastic material such as polybutylene terephthalate, reinforced polybutylene terephthalate and/or polypropylene etc, to provide mechanical support for the waterproof cordless electrical plug connector.
ii. The waterproof cordless electrical plug connector of claim 2 or any one of claims 4 to 10, when dependent on claim 2, wherein the shut off point of the main body finishes level with or short of the end face of the at least one seal assembly so that at least the end of the seal assembly is exposed.
12. The waterproof cordless electrical plug connector of any one of claims 1 to 11, wherein the intermediate portion is narrowed at the sealing area.
13. The waterproof cordless electrical plug connector of any one of claims I to 12, wherein each seal assembly comprises a plurality of discrete sealing portions for sealing the sealing area of said intermediate portion.
14. The waterproof cordless electrical plug connector of claim 13, wherein the discrete sealing portions are connected by an intermediate rib.
15. The waterproof cordless electrical plug connector of claim 14, wherein the intermediate rib has a reduced section relative to the discrete sealing portions.
16. The waterproof cordless electrical plug connector of any one of claims I to 12, wherein the at least one seal assembly is an elongate seal assembly for sealing the sealing area of S said intermediate portion.
i7. The waterproof cordless electrical plug connector of claim 2 or any one of claims 4 to 16, when dependent on claim 2, wherein each seal assembly comprises a peripheral profile to allow the main body to be positively secured andlor anchored to the least one seal assembly.
18. The waterproof cordless electrical plug connector of any one of claims I to 17, wherein at least two seal assemblies are provided and are alTanged in a tandem configuration to provide further redundancy or factor of safety should the integrity of primary seal assembly fails.
19. The waterproof cordless electrical plug connector of claim 18, wherein the at least two seal assemblies are provided substantially within the main body.
20. The waterproof cordless electrical plug connector of claim 18, wherein the at least one seal assembly is provided substantially within the main body and one or more other seal assembly is provided substantially outside the main body.
21. The waterproof cordless electrical plug connector of any one of claims I to 20, wherein the main body comprises an aperture for housing the proximal end of each electrical conductor assembly for electrical connection to said socket conductor of said corresponding socket connector.
22. The waterproof cordless electrical plug connector of any one of claims I to 21, wherein a resilient seal is provided to seal the main body to a sealing face of a component of the appliance to prevent ingress water therebetween.
23. The waterproof cordless electrical plug connector of claim 22, wherein the resilient seal comprises at least two sealing surfaces and the first sealing surface comprises at least one radially outwardly extending circumferential fin located between upper/lower ends of the resilient seal, which deform to take the shape of the sealing face of the component of the appliance.
24. The waterproof cordless electrical plug connector of claim 23, wherein the second sealing surface comprises at least one radially inwardly extending circumferential rib for sealing against the sealing face of the main body.
25. The waterproof cordless electrical plug connector of any one of claims 1 to 24, wherein the main body further comprises at least one boss to allow the main body to be secured or removably secured to the appliance.
26. The waterproof cordless electrical plug connector of any one of claims I to 25, wherein the main body andlor the corresponding cordless power base further comprises at least one housing for receiving at least one optical transmitter, receiver andlor transceiver to provide an optical coupling between the appliance and the corresponding cordless power base.
27. The waterproof cordless electrical plug connector of claim 26, wherein the optical coupling is a one-way or a two-way optical coupling to provide signal data between the appliance and the corresponding cordless power base.
28. The waterproof cordless electrical plug connector of claim 26 or 27, wherein the at least one optical transmitter, receiver and/or transceiver is mounted to the corresponding socket connector on the cordless power base.
29. The waterproof cordless electrical plug connector of any one of claims 26 to 28 when made dependent to any one of claims 22 to 24, wherein the resilient seal is made from an optically transmissive material.
30. The waterproof cordless electrical plug connector of any one of claims I to 29, wherein the waterproof cordless electrical plug connector comprises at least live and neutral electrical conductor assemblies.
31. The waterproof cordless electrical plug connector of claim 30, wherein the waterproof cordless electncal plug connector further compnses an electrical earth conductor assembly.
32. The waterproof cordless electrical plug connector of any one of claims 1 to 31, wherein the waterproof cordless electrical plug connector further comprises additional electrical conductor assemblies to provide a signal coupling between the appliance and a corresponding cordless power base.
33. The waterproof cordless electrical plug connector of any one of claims 1 to 32, wherein the distal ends of the electrical conductor assemblies are provided with tab terminals, rivets. planished portions or crimps for electrical connection to the at least one electrical component of the cordless electrical appliance.
34. The waterproof cordless electrical plug connector of any one of claims I to 33, wherein the proximal ends of the electrical conductor assemblies are arranged concentncally to provide a 3600 electrical mating or connection to the corresponding socket connector.
35. The waterproof cordless electrical plug connector of claim 34, wherein the proximal ends of the electrical conductor assemblies comprise a central pin conductor, at least one intermediate ring conductor and an outer ring conductor.
36. The waterproof cordless electrical plug connector of claim 35, wherein the central pin conductor is a live conductor, one of the at least one intermediate ring conductor is a neutral conductor, and the outer ring conductor is an earth conductor.
37. The waterproof cordless electrical plug connector of any one of claims I to 36, wherein the distal ends of the electrical conductor assemblies radiate outwardly and substantially terminate in a parallel formation so that the at least one seal assembly at the sealing area is arranged substantially side-by-side or linearly.
38. The waterproof cordless electrical plug connector of any one of claims 1 to 36, wherein the distal end of at east one electrical conductor assemNy radiates outwardly at a different angle from the distal end of at one other conductor assembly.
39. The waterproof cordless electrical plug connector of any one of claims 1 to 33, wherein the proximal ends of the electrical conductor assemblies are arranged linearly or non-concentrically to provide an orientation specific electrical mating or connection to the corresponding socket connector.
40. The waterproof cordless electncal plug connector of any one of claims 1 to 39, further comprising at least an apphance control, steam control or thermal control.
41. The waterproof cordless electrical plug connector of claim 40, wherein the appliance control, steam control or thermal control is integrated with said plug connector.
42. The waterproof cordless electrical plug connector of any one of claims 1 to 41, wherein the cordless electrical appliance further comprises a sealed compartment for housing at least one of: a heating element, mechanical or electronic controls, NTC, stirrer, mixer, blender, sensor, residual current protector, motor, chargeable or non-chargeable power supply. lift-off switch-off mechanism and/or wiring harnesses.
43. A waterproof cordless electrical appliance comprising the waterproof cordless electrical plug connector of any one of claims Ito 42.
44. A washable cordless electrical appliance comprising the waterproof cordless electrical plug connector of any one of claims Ito 42.
45. The cordless electrical appliance of claim 43 or 44, further comprising at least one sealed user actuable switch for operating one or more functions of the appliance.
46. The cordless electrical appliance of claim 43 or 44, further comprising at least one touch sensitive switch, such as a capacitive, resistive and/or piezo touch switch, for operating one or more functions of the appliance.
47. The cordless electrical appliance of claim 45 or 46, wherein the at least one sealed user actuable switch or touch sensitive switch is provided on the appliance and/or on a power base.
48. The cordless electrical appliance of any one of claims 43 to 47, further comprising a base component for receiving said waterproof cordless electrical plug connector.
49. The cordless electrical appliance of claim 48, wherein the base component is sealed to and/or removably secured or secured to the appliance.
50. The cordless electrical appliance of any one of claims 43 to 49, wherein the cordless electrical appliance is one or more of the following: 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, andlor hot water on demand appliances.
51. A method of assembling a waterproof cordless electrical plug connector for a cordless electrical appliance comprising the following steps: a. providing a plurality of electrical conductor assemblies, wherein each electrical conductor assembly comprises a proximal end for electncal connection to a socket conductor of a corresponding socket connector, a distal end for electrical connection to an electrical component of the cordless electrical appliance and an intermediate portion disposed therebetween; b. providing at least one seal assembly to seal over andlor around a sealing area of said intermediate portion; and c. moulding a main body partially or fully over and/or around at least said one or more seal assembly and the intermediate portion.
52. A method of assembling a waterproof cordless electrical plug connector for a cordless electrical appliance comprising the following steps: a. providing a plurality of electrical conductor assemblies, wherein each electrical conductor assembly comprises a proximal end for electrical connection to a socket conductor of a corresponding socket connector, a distal end for electrical connection to an electrical component of the cordless electrical appliance and an intermediate portion disposed therebetween; b. moulding a main body partially or fully over and/or around at least the intermediate portion; and c. providing at least one seal assembly to seal over and/or around a sealing area of said intermediate portion and to seal partially or fully against, over and/or around the main body.
53. The method of claim 51 or 52, wherein the at least one seal assembly and the main body are provided as part of a multiple stage moulding process.
54. The method of claim 53, wherein the multiple stage moulding process is a two-stage moulding process.
55. The method of claim 51 or 52, the at least one seal assemNy and the main body are provided as part of a single stage moulding process. such as a twin-shot moulding process.
56. The method of any one of claims 51 to 55, wherein the at least one seal assembly is made from an elastomeric material or from a resilient polymeric material, such as a polymer, polyamide. copolyamide and/or copolymer and the like.
57. The method of any one of claims 51 or 56, wherein the sealing area of said intermediate portion is provided with at least a recess, aperture, textured surface, roughened surface and/or etched surface to allow the at least one seal assembly to be positively secured, anchored and/or adhered to the sealing area.
58. The method of any one of claims 51 to 57, wherein the at least one seal assembly is directly moulded over and/or around the sealing area of said intermediate portion.
59. The method of any one of claims 51 to 57, wherein the at least one seal assembly is a pre-formed seal positioned over and/or around the sealing area of said intermediate portion,
60. The method of claim 59, wherein the at least one seal assembly is a pre-formed elastic and/or resilient seal comprising a reduced cross section, such that the pre-formed elastic and/or resilient seal is stretched over the sealing area of the intermediate portion to provide an additional compression force to enhance the sealing interface over the sealing area.
61. The method of any one of claims 51 to 60, wherein the main body is made from a rigid and/or engineered plastic material such as polybutylene terephthalate, reinforced polybutylene terephthalate and/or polypropylene etc, to provide mechanical support for the waterproof cordless electrical plug connector
62. The method of any one of claims 51 to 61, wherein each one seal assembly comprises a plurality of discrete sealing portions for sealing the sealing area of said intermediate port ion.
63. The method of claim 62. wherein the discrete sealing portions are connected by an intermediate rib.
64. The method of claim 63, when dependent to claim 51, wherein the intermediate rib is removed prior to moulding the main body partially or fully over and/or around the at least one seal assembly and the intermediate portion.
65. The method of any one of claims 51 to 61, wherein the at least one seal assembly is an elongated seal assembly for sealing the sealing area of said intermediate portion
66. The method of any one of claims 51 to 65, when dependent to claim 51, wherein each seal assembly comprises a peripheral profile to allow the main body to be positively secured andlor anchored to the least one seal assembly.
67. The method of any one of claims 51 to 66, when dependent to claim 51, wherein the main body shrinks after the moulding process as it cools to compress/clamp the at least seal assembly between the main body and the conductor to improve the sealing means.
68. The method of any one of claims Si to 67, wherein at least two seal assemblies are provided and are alTanged in a tandem configuration to provide further redundancy or factor of safety should the integrity of primary seal assembly fails.
69. The method of any one of claims 51 to 68, wherein the main body is provided with an aperture for housing the proximal end of each electrical conductor assembly for electrical connection to said socket conductor of said corresponding socket connector
70. The method of any one of claims 51 to 69, wherein the main body is provided with at least one boss to allow the main body to be secured and/or removably secured to the appliance.
71. The method of any one of claims 51 to 70, wherein the proximal ends of the electrical conductor assemblies are arranged concentrically to provide a 360° electrical mating or connection to the corresponding socket connector.
72. The method of any one of claims 51 to 70, wherein the proximal ends of the electrical conductor assemblies are arranged linearly or non-concentrically to provide an orientation specific electrical mating or connection to the corresponding socket connector.
73. A waterproof cordless dectrical plug connector assemNed according to the method of any one of claims 51 to 72.
74. A waterproof cordless electrical plug connector substantiafly as herein described with reference to any one of Figures 3 to 22 of the accompanying drawings.
75. A method of assembling a waterproof cordless electrical plug connector substantially as herein described with reference to any one of Figures 3 to 22 of the accompanying drawings.