WO2011018645A2 - Electrical appliances - Google Patents

Abstract

A heating element for a water heating appliance comprising a sheath portion attachable to a flange of the water heating appliance and a hot return portion positioned level with or above the point that the sheath enters the flange, wherein the flange includes an elongate dimple along which the hot return is positioned.

Description

Electrical Appliances

The present invention relates to electrical water heating appliances, and more particularly to portable electrically heated jugs and kettles incorporating immersed elements and controls therefore. Background to the Invention

Electric jugs and kettles with immersed elements can be classed as a mature product. In recent years with the advent of 'high end' 360° jugs and kettles with 'underfloor' heating, the more basic immersed element heating appliances have been focussed on the opening price point (OPP) area of the market. In the OPP area the trading margins are very narrow with, in some cases, an immersed appliance being used as a 'loss leader'. The volumes sold for each design can be very high with some retailers selling in excess of 500,000 units per annum of one design type. For reference in this patent all immersed element water heating appliances will be referred to as immersed jugs or jug kettles.

With the high volumes and low margins it is increasingly important to ensure that the component parts of the jug kettle are optimised to maximise the margins (or in some cases mitigate the loss) whilst still meeting the safety critical requirements for high powered appliances.

There have been many developments in this field during the last 30 years which include improvements to the controls, the elements, the appliance design and materials.

The safety controls for immersed elements include protection in the event that the appliance is switched on without water. This may take the form of a 'primary' bimetal protection and a secondary or back up protection provided by an additional bimetal or alternatively a secondary or back up protection based on a material that melts above a given temperature ie 'melting fuse'. The material for this melting fuse may be a plastic or alternatively a Eutectic material, for example, solder. Each of the bimetals and/or the melting fuse will interact with electrical contacts within the control or controls to disconnect the electrical power in an 'abnormal' condition, for example, if the appliance is switched on without water. Heat sink paste is traditionally applied to assist the heat transfer from the element into the control. It is essential that the overshoot heat from the element after the primary or secondary protection has activated is contained to a level that prevents damage occurring to surrounding components, for example, a plastic part of the jug kettle.

Figures Ia and Ib show a typical jug kettle element which includes an element sheath 1, an element flange 2 and electrical connecting means 3. A portion of the sheath 1 is positioned adjacent or attached to the wet side of the flange 2, which is the side of the flange that will be immersed in the water, in a corresponding position to the controls (not shown). This portion of the sheath 1 is called the hot return 4. The length and fixing method of the hot return 4 can be tuned to optimise that heat transfer to the control (not shown) and generally there would be a feature on the flange so that the position of the hot return 4 is consistent, this feature is referred to as the dimple 5. In normal conditions the water in the appliance would act as a heat sink, keeping the hot return area cooler than the temperature setting of the control. If the kettle was switched on, without water inside, then the hot return 4 would increase in temperature and the primary control would then disconnect the power to the element. In the case that the primary control failed then a second control, if fitted, would provide back up protection. The element seal (not shown) would also act as a heat barrier between the element flange 2 and the appliance (not shown). The element sheath 1 would be formed so that it fitted within the shape of the appliance and the two end portions of the sheath 1 would project into the dry side through the element flange 2 thus allowing for the electrical connections to be made to the electrical connecting means 6. Generally the attachment of the hot return 4 to the element flange and the sealing of the end portions of the sheath 1 to the flange 2 would be completed within the same welding or brazing process. In other instances, not shown, the hot return 4 may be mechanically attached to the element flange 2 and the sheath 1 mechanically crimped into the flange or sealed with an elastomer or 'O' ring type arrangement. The part of the sheath to which the electrical connection is made is a solid rod or cold pin 7, usually of a steel or stainless steel material, which is positioned within both of the end portions of the sheath 1, extending from the electrical connection point 3 through to the resistance wire (not shown). The cold pin 7 connects onto the resistance wire (not shown) which forms the active or heating part of the element sheath. The cold pin 7 is so called because this part is inactive and ensures that the elevated heat of the active part of the element is not conducted into the flange 2 then onto the control or appliance. The length of the inactive part is directly related to the material of the element sheath and flange typically either plated copper or brass or stainless steel. Generally the more heat conductive the sheath material the shorter the cold pin 7. The cold pin 7 is sealed into the end parts of the sheath 1 with an elastomer or ceramic plug 8. This ensures that the cold pin 7 is the correct electrical distance from the element sheath 1 and also prevents moisture entering the sheath 1 and compromising the compressed magnesium oxide powder (not shown) that acts as insulation between the live resistance wire and cold pin 7 and the sheath 1. The end part of the element sheath that includes the cold pin 7 and the electrical connecting means 3 is referred to as the cold tail 9. In figure Ia the electrical connecting means 3 of the element cold tail 9 is shown as a separate ferrule which is generally manufactured from, or plated with, a high conductive material such as nickel or silver. In other embodiments the end of the cold tail may be coated or plated directly with a higher conductive material. The ferrule or coated cold pin would then interface directly with a resilient spring contact within an integrated control. Other methods of connecting means to the cold tail may include tab terminals or welded connections.

The length of the cold tail 9 is also related to the position that the element sheath 1 enters the flange 2. If the sheath enters the flange 2 at a relative position above the hot return 4 (when the jug kettle is set in an upright position on a work surface) then this part of the sheath 1 could be exposed in low water conditions whilst the hot return 4 is still covered in water. In these conditions the portion of the sheath 1 above the water would overheat and could cause element failure or, alternatively, transfer the heat through the element flange 2 onto the appliance part. To avoid this, the cold pin 7 would need to be extended to a part of the sheath 1 that is lower than the hot return 4 as detailed in figure Ia.

The element assembly would be clamped to the appliance using the flange 2 as one part of the clamp face with the three bosses 6 as the clamping means. The bosses 6 would be riveted or welded onto the flange 2 and incorporate threads into which bolts can be attached. In other instances (not shown) the bosses can take the form of threaded bolts. In other element types fewer or additional fixing bosses 6 may be used.

There are predominantly two shapes of formed element sheaths, these are given the names butterfly 20 and spiral 21, examples of which are detailed in figures 2a and 2b. The butterfly type shape 20 is generally used in rectangular shaped appliances or appliances with a large footprint. The spiral element 21 is generally used in appliances with smaller footprints, for example plastic jug kettles.

The power output of each element is conditional upon the output of the resistance wire for a given length and voltage and the length of the sheath. The 'loading' of the element sheath is defined in watts density /cm^ and differs with the type of material used for the construction. If the sheath material is copper it is not possible to have as high a watts density as a stainless steel sheathed element therefore, where there is a limit on the length of active sheath, a wider diameter tube is required to ensure the watts density is within the limits for the material. Typically with a 2300 watt spiral copper sheathed element using 8mm external diameter tube and an active length of 375mm then the watts density would equate to around 24 watts/cm^. However a stainless steel sheath is capable of running at a higher loading, for example, 28 watts /cm^ so it is possible to achieve the same output with a sheath of 6.6mm diameter.

In Europe there has been a tradition for small, low cost, water heating appliances of a very basic rectangular or ovoid shape, usually around 1 litre in volume. The power cord was not detachable and in some versions could be wrapped around the base of the appliance for storage. Often there was no temperature sensor to switch off on boiling and where ancillary controls were fitted these were hard wired into the system.

The safety controls (not shown) were discrete components that were surface mounted on the back (dry side) of the element support flange 2 and hard wired to the element connecting means 3. The bimetal and melting fuse parts of the controls were generally positioned within the control housing so were not in direct contact with the element flange. As such there would be a lag between the temperature seen by the control means and the temperature sensing parts, however the power rating of these appliances was relatively low, typically, 1000 watts, therefore the overshoot temperatures after the primary or back up control had activated was not excessive. The element would be clamped into the appliance with a seal, and separate clamping flange using the element fixing bosses to apply the force required. Generally the element flange and the clamping flange were rectangular. With such a low output it was not necessary to use spiral elements even though the footprint of these appliances was quite small. To avoid long cold tails the hot return was often positioned at the side of, or above, the point that the sheath entered the element flange.

Gradually in Western Europe the market for this type of appliance has dwindled but these basic water heaters are still manufactured extensively in China; for example the S2015 available through Alibaba.com for an FOB price of $3.00. At such prices these types of appliances can still form the basis of the very low end of the jug kettle market in many countries worldwide.

Traditionally, in the UK, jug kettles were typically larger, for example, 1.7 litres and at higher wattages than the European counterparts. The UK jug kettles included automatic switch off on boil and some form of detachable cord. Controls (not shown) designed specifically for this type of appliance are detailed in GB2181598 and GB2194099, and would include other functions, for example, clamping means and electrical connection means including the earth connection. Elements and seals were designed to interface with the controls and were such that during assembly the three components formed a clamping arrangement that attached and sealed these parts into the appliance. During the assembly process resilient springs within the control made direct electrical contact with the electrical connecting means 3 of the element. The controls would also include access for the electrical power via a plug or cordless connector and may include a steam or temperature sensor, with the complete component referred to as an integrated control. The safety part of the controls would include 'bimetal' protection in case the appliance is switched on without water and more latterly a secondary bimetal or back up melting fuse. Each of the bimetal and the melting fuse interact with electrical contacts within the control to disconnect the power in 'abnormal' conditions. Whereas in the European type control the bimetal and melting fuse material were not always directly mounted against the element flange. With the UK type control the bimetal and thermal fuses were able to make direct contact with the element flange 2 - allowing the control to respond faster in abnormal conditions and this enabled more powerful elements to be incorporated in the appliances. The higher powered UK elements could be subjected to the same abnormal conditions as the European versions and would include cold tails to ensure that the active part of the element did not cause any overheating problems. The element sheaths 1 , in the UK, were usually manufactured from copper with the element flange 2 from brass and then the whole assembly chromed or nickel plated. The brass flange 2, having high heat conducting properties, would speed up the response time of the control but this could cause problems with overshoot temperatures melting the plastic bodied appliances, in which case the seal thickness could be increased to act as a heat barrier.

For controls including bimetals that can be reset then the appliance could be reused after an abnormal condition. For appliances including a thermal fuse as back up protection then these could not be reused once activated. In which case the melting fuse was designed to trip well above the primary bimetal setting to avoid any nuisance tripping of the melting fuse. The balance between the element power, the hot return, the position of the element sheaths in the flange, the bimetal and melting fuse was critical - too little heat transfer and the element may rupture before it was safely disconnected - too much and the thermal fuse may nuisance trip. With the early integrated controls including melting fuses it was not possible to design an interface with the element such that the cold part of the sheath entered the element flange below the hot return and it was not possible to design an element and control combination that functioned at 3000 watts and these limitations have set the standard for all integrated controls manufactured since that time.

One of the first examples of an integrated control including a thermal fuse is detailed in GB2181598.

The limitations of the control and element interface meant that the element sheaths had long cold pin portions 7 which extended the overall length of the element and added considerably to the material cost of the element. The longer sheaths not only affected the cost but also the size of the appliance in that the longer sheaths needed a larger footprint, which in turn increased the cross sectional area of the appliance.

The position of the cold tails above the hot return caused further problems in use, in that under abnormal conditions, particularly when the element was subject to scale, then heat could transfer up through the cold tail into the flange and then onto the controls via the attachment screws. In some conditions the heat may be sufficient to soften the plastic of the integrated control housing and result in the element sagging away from the control which could expose live parts and could also allow water to leak into the electrical enclosure. Further measures were required to prevent this occurrence which included steel rather than less expensive but more conductive brass screws to attach the control to the element bosses, washers to act as a heat barrier between the bosses and the screws, additional metal brackets to spread the load between the end of the screws and the plastic parts and thicker seals so that the plastic bodied appliances did not melt. All of which added cost to the appliance.

The control detailed in GB2181598 was designed to interface with elements made from high conductive materials and may require an additional heat bridge to function correctly at higher wattages if used in conjunction with elements made from lower conductive materials such as stainless steel.

The proprietors patent GB2194099 details a control system with melting fuse which functions with elements made from both low and high conductive materials without the need for additional heat bridges.

Patent EP066981 details the proprietor's CS21 cordless connector which incorporates an integral cord grip and enclosure so that a cordless base can be manufactured from a one piece moulding.

Other later patents owned by the proprietor for integrated controls and corresponding cordless connectors include GB2387492 and GB2376575

During the 1990's a lot of work took place to develop stainless steel elements capable of being formed into spiral shapes at power of over 2000 watts to interface with integrated controls. This move came about because of the perceived health issues of the uses of chrome and nickel plated material in drinking water plus the environmental issues of industrial plants involved in the plating process.

There were technical difficulties to overcome in ensuring the correct heat path between the element and the control and production difficulties in order to ensure the capability of the welding and brazing process in the hot return area.

The low heat conductivity of stainless steel made the elements more susceptible to failure through overheating, and resulted in the need for longer cold pins than those required in copper sheathed elements.

The cost of manufacture of the stainless steel elements was greater in Europe than the plated copper therefore, despite the health issues many markets were not prepared to pay the premium for stainless steel. As the kettle market grew, the production of jug kettles with integrated controls spread across Europe and onto the Far East, principally into China where the labour and sub assembly costs were low.

Efforts to optimise the manufacturing and assembly cost of immersed jugs were put on hold as more and more product moved to China. However, in recent years, costs in China are on the increase and the international financial crisis has put pressure on pricing and margins and investment in new products.

High fuel costs have dramatically increased freight charges so that box size and the number of boxes in a container are now critical. Typically the maximum number of boxes containing UK type jug kettles that can be transported in one 40 foot container is 8,000.

Generally the UK style jug kettle incorporating automatic switch off on boiling and cordless connecting means has become the preferred OPP jug kettle for the European retail stores. However, the existence of the low cost basic European type jug kettle, which is still available, provides further pressure on the FOB prices of UK style jug kettles.

There are six main drivers to design more cost effective appliances:

1) Rising labour costs in China.

2) Rising material costs.

3) World financial crisis that effectively reduced capital available to the Chinese manufactures.

4) Transport Costs

5) Consumers demanding more value for lower cost.

6) The increase of global retailers such as Walmart in the supply chain.

Early methods to optimise the cost of UK type jug kettles resulted in designs that were unappealing and there is a need to put forward construction and assembly methods whereby the complexity of the appliance is reduced while providing the above discussed functionality, so that, for example, the moulded parts count is reduced considerably but the design is still aesthetically pleasing.

There is also the need to reduce the environmental impact in the manufacture of the heating elements including the amount of materials used, the manner in which it is processed and the energy used during the manufacturing process.

There is also the need to develop an integrated control that will interface with the optimised elements and also meet more stringent approval test requirements.

Statements of Invention

According to one aspect of this invention there is provided an immersed jug kettle in which the appliance includes only four moulded appliance parts and this appliance can be assembled without the need for additional screws, other than those required to attach the integrated control to the element and the cordless connector to the cordless base.

According to another aspect of this invention there is provided an immersed jug kettle in which the appliance includes only five moulded appliance parts and this appliance can be assembled without the need for additional screws, other than those required to attach the integrated control to the element and the cordless connector to the cordless base.

According to another aspect of this invention there is provided an immersed jug kettle in which a removable lid includes a portion that forms part of the grip of the handle when the lid is placed on the appliance.

According to another aspect of the invention there is an appliance where the back cover of the appliance is secured to the control system using the same screws that secure the control system to the element.

According the another aspect of the invention there is provided a jug kettle design that optimizes the size and profile of each part so that the appliance gift box is reduced in size and enables additional boxes to be transported in a standard container load. According the another aspect of the invention there is provided a cordless connection system in which the cordless base is of a size that it will fit into the appliance carton without the need to increase the carton size.

According to another aspect of the invention there is provided an integrated control and corresponding element in which the hot return is positioned above the point that the element sheath enters the element flange.

According to another aspect of the invention there is provided a heating element in which the interface of the sheath to the element flange is secured using a laser welding process.

According to another aspect of the invention there is provided an integrated control and corresponding spiral element in which the element is up to 23% shorter than a standard immersed spiral element.

According to another aspect of the invention there is provided an integrated control and corresponding butterfly element in which the element is up to 16% shorter than a standard immersed butterfly element

According to another aspect of the invention there is provided an integrated control and corresponding element in which the element is rated at 3000 watts at 240 volts.

According to another aspect of the invention there is provided an improved earth connection that enables an integrated control assembly to meet a 40 amp earth grounding test.

According to another aspect of the invention there is provided a safety switch mechanism where a steam switch and a dry boil push rod are allowed to independently act on the same set of contacts via an intermediate push rod.

Brief Description of Drawings

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.

Figures Ia and Ib respectively are schematic representations of prior art element configurations. Figures 2a and 2b respectively are schematic representations of prior art butterfly and spiral element profiles.

Figure 3 a to 3 c respectively are isometric views of a jug kettle of the first embodiment.

Figure 3d is a schematic view of the mould tooling draw directions for the first embodiment.

Figure 3 e is an isometric view of an alternative to the first embodiment in which there is a separate cover that is secured to the control system using the same screws that secure the control system to the element.

Figure 4 is a plan view of the gift box shape for jug kettles of the first embodiment. Figure 5a to 5c respectively are isometric views of a jug kettle of the second embodiment.

Figure 5d is a schematic view of the mould tooling draw directions for the second embodiment.

Figure 5e is an isometric view of the third embodiment in which there is a jug kettle with a reduced size cordless base moulding.

Figure 6 is a plan view of the gift box shape for jug kettles of the second and third embodiment.

Figures 7a to 7c respectively are schematic representations of the cold pin length requirement for butterfly elements.

Figure 7d to 7f respectively are schematic representations of the cold pin length requirement for spiral elements.

Figures 8a and 8b respectively are isometric views of controls and element interface of the fourth and fifth embodiment.

Figures 9a and 9b respectively are front and back views of a control of the fifth embodiment.

Figure 9c is a schematic representation of an alternative push rod system for the fifth embodiment. Figure 10 is an isometric view of an alternative embodiment comprising the second embodiment incorporating the element and control assembly of the fourth and fifth embodiment.

Figures l l a and l ib are schematic illustrations of alternative heater element embodiments

Figure 12 is a schematic illustration of a further alternative to the heater element embodiments.

Detailed Description of the Embodiments

In the following description, functionally similar parts carry the same reference numerals and letters between different embodiments.

The description focuses on novel aspects of embodiments of the present invention. Further information relating to background technical and design aspects may be found in the above mentioned patent applications.

First Embodiment

Figures 3a to 3c show a jug kettle of the first embodiment with a minimum part count. The shape of each part is optimised so that when assembled the cross section of the whole appliance is reduced providing a less complex appliance and simplified manufacturing processes. In this embodiment, the jug kettle appliance is ovoid in shape and is made up of four plastic moulded components, as discussed below.

The first plastic moulded component is the jug body 30 which as illustrated incorporates an inserted moulded front water window 31. The jug body includes a spout portion 32, a handle portion 33, a reservoir portion 34, a steam tube portion 35, a control portion 36, and a back cover portion 37. The shape of the spout portion and handle are optimised so that they do not unduly lengthen the gift box in which the appliance is packaged. An orifice 41 is provided within the reservoir portion for assembly of the spiral element 21 with the proprietor's X5 integrated control 80. Steam reaches the control 80 via the steam tube 35. The control 80 incorporates three fixed electrical contacts (not shown) that are housed in the cordless inlet 94 which interface with corresponding resilient springs in the cordless connector 95. Access holes and slots 38, 39 and 40 respectively are provided for the switch actuator 70 and for the three screws (not shown) that secure the control 80 to the element 21. The access part 38 may be a slot or may be two separate holes sufficiently large to provide access for the screws and screw driving means. These holes or slots may be left exposed - but in the preferred embodiment a label 75 including, for example a brand or logo, may be positioned to cover the hole or holes 38. In figure 3b the bottom screw is accessed through a slot 40 with a corresponding cosmetic cover 51 provided on the cordless base to hide the slot 40 when the jug kettle is positioned on the cordless base 50. In other embodiments it is envisaged that the access holes for all three screws may be covered by labels or logos with the option for a cosmetic cover 51 in the base 50 so that one or more of the labels or logos 75 cannot be seen when the appliance is on the base 50. The area around the switch actuator slot may include additional details (not shown) that would act as pivot point for switch actuator 70 if required.

In the first embodiment the water window 31 is positioned at the front so that one water window can be seen from both sides preventing the need for two water windows. In embodiments that include one or more water window then it is possible to change the shape of the water window by following the principles laid down in the proprietors patent GB2431612 which details methods of insert moulding water windows such that different water window shapes and styles can be applied to a jug kettle body without the need to retool the main body moulding. In a further alternative, the entire body 30 can be moulded in a translucent or transparent plastic material removing the need for a water window. Indication marks for the water level can be included within the moulded plastic parts or printed on the parts during the manufacturing process.

The handle portion 33 is hollow formed with a 'C shaped type cross sectional profile. The 'C shaped cross section not only enables the handle to be formed with simple tooling, but also shortens the overall length of the product so enabling a smaller gift box. The back part of the handle 33 may include additional features, for example slots, to act as gripping points for the fingers or the hand. The user's thumb can be positioned on the extended part 64 of the lid 60. The second moulded plastic component is a one piece lid 60 which incorporates an integrally moulded mesh 61 that will act as a water filter, as part of the spout baffle 62. It is expected that the appliance will be filled through the spout, however the lid 60 may be removable and may be secured by an interference or click fit (not shown). The spout baffle 62 may slot into details formed in the spout 32 to assist in positioning the spout baffle 62 relative to the spout 32. Removal of the lid will be assisted by a recessed finger grip 63. The lid also includes a back part 64 that may act, both visually and functionally, as the top part of the handle. In further embodiments it is envisaged that the back part 64 may be extended further to suit the design and handling requirements of the jug kettle. The back part 64 may include features that assist in the positioning of the users thumb and may include a feature to assist in removing the complete lid 60.

The lid 60 is flat in profile so that it does not increase the overall height of the gift box. In other embodiments or designs where a domed shape lid is preferred then the lid can be designed so that it can be positioned within the jug body 30 when the appliance is in the gift box.

The third moulded plastic component is the switch actuator 70 which acts as the user interface for the appliance. The actuator 70 will be installed directly onto the control 80 during the assembly of the appliance. The back part of the actuator 70 will be positioned on the inside of the slot 38 so that the inside of the appliance cannot be seen through the slot 38 when the actuator 70 is in either the 'on' or 'off position. The back part of the actuator 70 may be coloured or textured to indicate, for example, when the actuator 82 is in the 'on' position.

The fourth component is the one piece cordless base 50 which will house the proprietor's CS21 cordless connector 95. The guidelines for installation of CS21, are well known to the industry, and enable the CS21 to be installed, using two screws, into a one piece base moulding so that the finished assembly can meet the cord grip and cord pull requirements of the most relevant international standards. In addition there is also provided a cosmetic cover 51 that corresponds to the slot 40 in the appliance body 30.

Figure 3d demonstrates how all the features of the appliance body can be moulded within one tool. The core 101 for the reservoir part 34 will move upwards. This core may include a side acting part (also referred to as a sliding core) for the element orifice 41. The core 102 for the steam, control and back cover parts 34, 35 and 36 respectively will be downward acting and may include one or more side acting parts for forming the features 38, 39 and 40. The core for the handle 33 is split into two; the first core 103 moves upwards and the second 104 moves outwards. In a simpler designed handle it may be possible to combine the two cores 103 and 104 into one core that moves upwards and outwards. In a further embodiment (not shown) it may be possible to form the vertical part of the handle 33 as a tube shaped cross section as opposed to a 'C shaped cross section in which case the tooling would withdraw in an upward direction. In this case the back part 64 of the lid 60 could be configured to close off the horizontal part of the handle.

Figure 3e illustrates an alternative arrangement in which an additional small cover is employed so that there is easier access to the control for assembly. The bottom screw for the control 80 may be installed before the cover 48 and the top two screws may be installed through the cover 48 so that when the screws are tightened they secure the cover 48 to the control 80 and the control 80 to the element 21. There may be issues with heat transfer from the element 21 through the screws and into the cover 48 but these may be mitigated by additional insulation means or alternatively by incorporating an element manufactured in low conductive materials. The cover could include pivot points (not shown) for the switch actuator 70 if required. The access 39 for the screws may be covered by a label or logo 75.

Freight charges are a major cost in sourcing European product from the Far East and the shape of the first embodiment has been optimised to reduce the cubic volume of the gift box.

Figure 4 shows a plan of the gift box shape for the first embodiment. The illustration assumes that the complete jug kettle is positioned on the cordless base within the gift box.

Dimension A is 136mm

Dimension B is 207mm.

Height is 222mm.

With the above dimensions it will be possible to fit over 8,700 in a 40 foot container and increase of around 18% over the present accepted maximum. Second Embodiment

The jug kettle appliance of the second embodiment is round in shape and each part is optimised so that when assembled the cross section of the whole appliance is reduced enabling a smaller gift box size.

The second embodiment is illustrated in Figures 5 a to 5 c and is functionally similar to the first embodiment including the same element 21, control assembly 80 and cordless connector 95. Many of the plastic moulded parts also have common features and the following description will concentrate on the new features of the second embodiment compared with the first embodiment.

The jug kettle is made up of five moulded components:

The first moulded plastic component is the jug body 30. This shape and mould tool design is more conventional than the first embodiment but does include the added feature of the entire back part 49 of the reservoir being formed from translucent or transparent plastic that is insert moulded into the reservoir portion 34. This back part 49 acts as a visible water window 47 that can be viewed from either side of the appliance. The steam tube 35 is also formed within the back part 47. As with the first embodiment the tooling could accommodate different shapes for the insert moulded back part 49 or alternatively the body could be moulded from translucent or transparent material.

The second moulded plastic component is the back cover 46 which also includes the handle and a slot 38 for the switch actuator. The area around the slot 38 will include pivot points (not shown) to attach the switch actuator. It is intended that the back cover 46 will include click fits (not shown) and/or other plastic fixing arrangement to secure the back cover 46 to the jug body 30. For additional security (not shown) it may be possible for the back cover 46 to be secured to the control 80 with the two top screws in the same manner as cover 48 as illustrated in figure 3e. When attached to the jug body the back cover acts to obscure the centre part of the back part 49 so that the two outside planes appear on either side of the jug kettle as water windows 47. If the body 30 is moulded from translucent or transparent material then the back moulding 46 may still be moulded in opaque material in order to define the shape of the appliance. In this case the back part 46 could extend further around the jug body, for example at an angle, to suit the design needs of the appliance.

The third moulded plastic component is the lid 60. As illustrated this does not include a handle cover moulding 64 but in a further embodiment this may be included.

The fourth moulded plastic component is the user actuator 70, as illustrated this switch includes bosses 71 so that the actuator 70 may rotate about pivot points (not shown) included in the back cover 46.

The fifth moulded plastic component is the one piece cordless base 50.

Figure 5d demonstrates how all the features of the appliance body 30 and the back cover 46 can be moulded.

The tool design assumes that the body 30 will be moulded in one part without an insert moulded back part 49. The core 101 for the reservoir part 34 will move upwards. This core may include a side acting part for the element orifice 41. The steam tube and back core 106 will move outward and may include a side part for the element orifice 41 as an alternative to a side acting part in core 101.

The back cover part 46 would also include two cores. The first core 105 will form the complete handle 33 and will withdraw in a circular motion. In another embodiment the rotating core of the top part of the handle may be truncated and a corresponding part 64 added to the back of the lid 60 to close off the top of the handle. The second core 107 will move sideways and in doing so will form the access for the switch actuator 38.

Figure 6 shows a plan of the gift box shape for the second embodiment. The illustration assumes that the complete jug kettle is positioned on the cordless base within the gift box.

Dimension A is 143mm.

Dimension B is 184mm

Height is 224mm.

With the above dimensions it will be possible to fit over 9,200 boxes in a 40 foot container an increase of around 24% over the present accepted maximum. The improvement over the first embodiment is because a round jug is more space efficient than an oval shaped jug. Third Embodiment

It has already been detailed that savings can be made in transport costs by reducing the size of a boxed appliance. The cordless base can take up to 10 % of the box volume if positioned underneath the jug kettle. One way of reducing the impact of the cordless base is to place the base inside the jug kettle, however there are two main problems with this:

i) A base that is designed to fit underneath a round jug is not always able to fit inside the jug body so the jug body needs to be made larger, which may negate the space saving. Alternatively it may be possible to fit an oval shaped base into an oval shaped jug however it can be seen from the first and second embodiments that a round shaped jug is more space efficient than an oval shaped jug therefore designing an oval spaced jug in order to enable the cordless base to fit within the jug may be counter productive. ii) There have been occasions in the past for field returns where the customer could not see the cordless base within the gift box and the jug returned for this reason. Whereas this may appear a minor issue, in reality the cost of receiving and processing a returned product has to be factored into the overall cost structure and it is particularly important when the margins are low, therefore any saving in transport costs may be lost if the initiative results in a field return.

An alternative position for the cordless base in the gift box may be found in the V shaped area 54 in figure 4 and figure 6, however the space available is marginal for a base that is as wide as the bottom of the kettle.

The third embodiment as illustrated in figure 5e details a reduced size cordless base 52 that fits within the back part of the appliance immediately beneath the cordless inlet 94 of the control 80. A reduced size cordless base 52 as illustrated will be small enough to be positioned in the boxes of Figures 4 and 6 within the area marked 54. In this embodiment, the cordless base 52 has a base footprint size which is smaller than the base footprint size of the jug body 30. The vertical cross section of the jug body 30 may be modified to form a sump around the front part of the cordless base 52 so that the overall height of the body 30 may be reduced in height.

The size of the cordless base 52 could be reduced further so that the complete cordless base 52 and connector 95 may fit within the back cover moulding 46, in which case the jug body 30 would sit directly on the work surface.

The reduced sized bases may be susceptible to movement on the worktop and may include rubber feet or possible 'suckers' to avoid this issue. In addition there may be an additional interface feature, linked for example to the switch actuator that positively aligns or latches the connector 95 with the connector inlet 94 and then releases the connection when the kettle needs to be removed from the cordless base.

The connector 95 and appliance are used for illustration purposes only with this embodiment applicable to all connector types and appliance shapes including 360 degree connectors for example the proprietor's CS4 and CS7 ranges.

The box size for the third embodiment will be approximately 3% smaller than the second embodiment which would result in an additional 300 boxes, making a total of 9,500 that could be transported in a 40 foot container.

Optimizing Element Configurations

It has already been stated that cost savings can be made in the material costs of an element by configuring the element so that the cold tails 9 are positioned below the hot return portion 4.

An important safety issue with immersed elements is to ensure that any part of the sheath 1 , above the hot return 4 (when the jug kettle is in an upright position set on a work surface), is prevented from overheating when a part of the sheath 1 is above the water level at a point when the hot return 4 is below the water level. This abnormal condition may occur, for example, if the appliance is not filled to the correct level.

Figures 7a to 7f respectively are schematic representations of the length of the cold pins 7 in both butterfly and spiral elements. Figure 7a illustrates a butterfly element 20 in a configuration with the hot return 4 below the point at which the sheath 1 enters the flange 2.

Figure 7c illustrates a butterfly element 22 in configuration with the hot return 4 above the point at which the sheath 1 enters the flange 2.

Figure 7b is a schematic plan view of both figures 7a and 7c.

Figure 7d illustrates a spiral element 21 in a configuration with the hot return 4 below the point at which the sheath 1 enters the flange 2.

Figure 7f illustrates a spiral element 23 in a configuration with the hot return 4 above the point at which the sheath 1 enters the flange 2.

Figure 7e is a schematic plan view of both figures 7d and 7f.

As illustrated in Figures 7a to 7f, dimensions of the cold pin 7 length are indicated for each different configuration. As illustrated, the dimensions X, Y and Z are measured from a point on the wet side of the flange 2 at which the sheath 1 enters the flange 2 to a point where the cold pin 7 meets with the resistance wire (not shown).

In Figures 7a and 7b, dimension Y is the cold pin 7 length for a butterfly element 20 with the hot return 4 below the point at which the sheath 1 enters the flange 2.

In Figures 7d and 7e. dimensions X and Y are the cold pin 7 lengths for a spiral element 21 with the hot return 4 below the point at which the sheath 1 enters the flange 2.

In Figures 7c and 7f, dimension Z is the cold pin 7 length for both butterfly 22 and spiral 23 elements with the hot return 4 above the point at which the sheath 1 enters the flange 2.

As those skilled in the art will appreciate, although it might be expected that dimensions X and Y would be the same for elements of the same wattage manufactured in either high conductive materials, for example copper, or low conductive materials, for example stainless steel, this is not the case.

There are two main reasons for this:

1) Loading (watts density) of the element 2) Level of temperature reached during the abnormal condition, and the proximity of temperature reached to the point at which the element sheath will rupture.

With copper sheathed elements the loading of the element is lower than with stainless steel and the higher conductive material helps dissipate the increased heat of any active part above the water. The cooling or heat sink effect of the water is transferred through the higher conductive material - which helps keep the overall temperature of the sheath below the critical level.

Manufacturers are aware of this phenomenon and it is known in the industry to minimise dimensions X and Y in copper sheathed elements. Generally this is done within the same element shape which effectively lengthens the active length accordingly. The material cost of the cold pin 7 is higher than the cost of the resistance wire therefore there are two benefits, one is the reduction in material cost and the other a lowering of the watts density. The more the manufacturers shorten the cold pin 7 the greater the risk for element rupture. For the purposes of the tables it will be assumed that the cold pin lengths for the copper sheathed element will be 20mm shorter than those of stainless steel elements.

With stainless steel sheathed elements the loading is higher, which means that the element runs at a higher temperature. The low conductivity means that very little heat is dissipated along the length of the element sheath 1 and the heat sink effect of the water is reduced. If a small portion of sheath 1 above the water level is active the sheath 1 will quickly overheat to a critical level and can rupture. Again the manufacturers are aware of this and generally the cold pins 7 comply fully with dimensions X and Y.

Dimension Z will be similar for both copper and stainless steel elements because the active part of the sheath 1 is below the hot return 4 therefore can never become exposed whilst the hot return 4 is submerged.

Table 1 is based on the dimensions of figures 7a to 7c and 7d to 7f as indicated. As illustrated in Figures 7b and 7e, there are two cold pins in each element and these are measured separately. As those skilled in the art will appreciate, these dimensions may vary in 'the field' and the benefits will be proportional. Table 1

It can be seen that positioning the hot return 4 above the position in which the sheath 1 enters the flange 2 results in a considerable reduction in cold pin length.

It was disclosed above that 'typically' the active length of a 2300 watt element is approximately 375mm and based on this length Table 2 details the overall length of sheath for each configuration. Table 2

It can be seen that the percentage savings in overall length of the elements 22 and 23 over elements 20 and 21 is significant - from 11 up to 23%.

These 'savings' can be exploited in three ways:

a) Reduce the size of the element - thus saving in material costs.

b) Increase the active length so increasing the element output for the same original shape. For example the power output of a 2300 watt stainless steel element could be increased to 3000 watts without increasing either the original length or the watts density.

c) Reduce the loading of the element so making it more tolerant to abuse conditions.

It has previously been detailed that, to date, integrated controls suitable for UK type jug kettles have, for technical reasons, always been configured to interface with elements of the type 20 and 21 where the hot return 4 is below the position the sheath 1 enters the flange 2. The main reason for this is that the element and integrated control interface is more critical for type 22 and 23 elements.

The inventors believe that these problems can be overcome in three ways:

Improve the capability of the element manufacturing process, improve the capability of the control or improve interface between the control and the element

The critical area in the assembly process of an element is the integrity of the contact of the hot return 4 to the flange 2. If the contact is less than required then the control may not switch in time, if the contact is greater than required then the control could nuisance trip.

Traditionally the hot return 4 and ends of the sheath 1 are brazed or welded onto the flange 2 both processes in which it is very difficult to fully control the critical areas and both involve a great deal of energy or heat to carry out the process.

The most effective method to achieve improved elements would be to laser weld the hot return 4 to the flange 2. The laser welding process improves accuracy - so that the interface is always consistent and is focussed so that the weld is only present in the areas required reducing the stress on the element as a whole and also reducing the energy costs.

Fourth Embodiment

According to the fourth embodiment there is provided a stainless steel immersed element in which the hot return 4 is above the position that the ends of the sheaths 1 enter the flange 2, and these parts are attached to the element flange 2 utilising a laser welding process. In this embodiment, dimension X of the cold pin 7 is between 5mm and 30mm with the optimum length being 15mm.

Whereas the laser welded process has been put forward as a method to optimise the use of elements where the hot return 4 is above the position in which the sheath 1 enters flange 2, the process is not limited to this element type and will have advantages in all types of immersed element assemblies including the type where the hot return 4 is below the position in which the sheath 1 enters the flange 2. Laser welding is also advantageous for materials, for example copper, that would normally be very difficult to weld and traditionally relies upon other methods of joining for example brazing.

Fifth Embodiment

As those skilled in the art will appreciate, if an element of the fourth embodiment is to be put forward then it will be necessary to develop a corresponding control that will interface with the element of the fourth embodiment in such a way that it meets the required safety critical standards, performs in a manner that is acceptable to the customer and can exploit the 3000 watt capability.

The new integrated control 81 and the new cordless connector 96 are based on improvements to a combination of features put forward in the proprietor's patents GB2194099, GB2387492 and GB2376575 in addition new interface and connection methods.

As illustrated in Figures 9a and 9b, the control 81 will incorporate an 'X' type dry boil blade 84 that will act against a push rod (not shown) as the primary protection means. The electrical connection between the control 81 and the spiral element 23 will be via the resilient spring contacts interfacing with the ferrules 3 of the element 23. The control 81 will be connected to the element 23 by the three screws 79 which will pass through the control 81 via the holes 87 and connect into the bosses 6. The peripheral flange portion 92 will act as one part of the clamping means with the flange 2 acting as the corresponding clamping means in the element 23 and the assembly made water tight by the compression of the seal 78. Once assembled the dry boil blade 84 will be held in position against the element flange 2 by a combined housing and melting fuse 90. Both the dry boil blade 84 and the melting fuse 90 will interact with corresponding contacts in the integrated control so that in an abnormal condition the power to the two resilient spring contacts 91 will be disconnected.

In order to improve the capability of the integrated control it is necessary to be able to easily modify the parameters and relationships between the bimetal, the melting fuse and the position and length of the hot return.

The size and shape of the melting fuse parts 90 in contact with the flange 2 will be configured to interface directly with the elongated dimple 5 on the flange 2. The elongated dimple 5 is typically between 5mm and 35mm long, 2mm and 10mm wide and lmm and 5mm deep. In other embodiments the dimple 5 may be recessed into the flange 2, the elongate dimple 5 facing in a direction towards the control 81 so as to form a recess for the hot return. In other embodiments the welding process may be carried out above or below the dimple 5 and in further embodiments a dimple may not be included on flange 2. The hot return 4 can be lengthened or shortened and laser weld 11 can be tuned to ensure the optimum heat transfer. The laser welding technique being particularly suited to controlled adjustments to ensure the correct heat flow from the element to the bimetal and melting fuse. The sheath 1 may also be connected to the flange 2 by a laser weld 12. The material of the melting fuse can be chosen from a range of plastic materials with different melting points including Stanyl and Amodel. Dry boil push rod material may be manufactured from a range of materials including plastic or ceramic.

In an embodiment, the internal switching function (not shown) may be similar to the proprietor's X5 integrated control 80 in which the dry boil push rod acts upon one pair of internal electrical contacts and the steam switch actuator acts upon a second pair of internal electrical contacts. As an alternative, a new switch arrangement is as illustrated in figure 9c, in which both the bi-metal push rod 114 and the steam switch actuator 82 may independently act upon a single pair of contacts in the control 81.

This is achieved by the introduction of an intermediate pivoting push rod 115 with one portion 119 that acts upon a portion of a pair of contacts 117 mounted on respective resilient spring members. As those skilled in the art will appreciate, one or both of the members may be resilient to enable the pair of contacts 117 to effectively act as a switch for the control 81. The end portion 119 of the pivoting intermediate push rod 115 is positioned between the dry boil push rod 1 14 and the pair of contacts 1 17. In the case of an abnormal condition (such as overheating due to dry boil) as detected by the bi-metal blade 84, the intermediate push rod 115 will then act as a shunt to transfer motion from the bimetal push rod 114 onto a resilient spring portion of the pair of contacts 117 (as schematically illustrated for clarity in Figure 9c) to disconnect the power from the control circuit in control 81. The steam switch actuator 82 has two distal points, the steam blade actuation point 111 and the push rod 112 which pivot about point 110. The push rod 112 interacts with a second end portion 118 of the intermediate push rod 115. In the case that the steam bi-metal (not shown) activates then the steam switch actuator applies a force onto the intermediate push rod 115 which then rotates about the pivot point 116 at which time the other end of the push rod 119 acts upon the same resiliently sprung portion of the contact pair 117 and disconnects the power from the control circuit. The mechanism is such that the dry boil and steam switch act independently and will not interfere with the function of the other part. As those skilled in the art will appreciate, this arrangement is not specific to control 81 and can be employed in any suitable integrated control.

In alternative embodiments the dry boil push rod 114 may act directly onto the contacts 117 without the need to for the end of the push rod 119 to act as a shunt.

The connection of the control 81 to the cordless connector 96 will be via live and neutral connectors 88 and 89 which form part of the control circuit. The earth connection 85 is connected directly to the element boss via an earth link 86. New standards have upgraded the requirement of earthing so that any earth connection has to be capable of a 40 amp earth grounding test for a duration of two minutes.

Whereas it is well known that by the use of expensive low resistance contacts such as silver or gold it is possible to meet the 40 amp requirement the proprietors have developed a lower cost alternative utilising low melting point metals or alloys. It has been found that when one or both of the connecting points is plated or coated with a low melting point metal or alloy the self heating effect of the high resistance connection causes the plating to melt and which increases the conductivity of the connection. As the conductivity increases the self heating decreases so the temperature decreases, as such the connection hovers about the melting point of the coating without ever fully generating enough heat to cause the coating to fully melt. It has been found that the optimum plating thickness is between 4 and 6 microns although it is expected that this will function within the window of 1 to 15 microns.

The optimum material will melt within the temperature range of 225 and 325 degrees with tin or tin alloy being particularly suitable. Alternatively other alloys, particularly eutectic alloys may also be specified.

The cordless connector 96 interfaces with controls 81 in a vertical manner - and the connector 96 is designed so that its horizontal position within the appliance can be easily modified to suit different design requirements, for example, in some jug kettles the element may need to be lowered to reduce the minimum water level.

The cordless connector 96 may also be configured to incorporate the same principle of cord grip as the CS21 cordless connector 95.

The rating of the complete integrated system may advantageously be suitable to enable 3000 watt elements.

The control 81, as illustrated, includes an integral steam control including a steam bimetal 83 however the control may also be configured so as to interface with a remote mounted steam or temperature control.

The seal 78 acts to seal the element into the appliance and also acts as a spacer between the control 81 and the element 23. The narrower the seal the lower the cost for the seal material. It is expected that utilising a stainless steel element will reduce the mass of the seal by 50%. This narrow seal 78 will reduce the required length of the element bosses 6 with resultant reduction in cost. For example reducing the seal thickness by 2mm will reduce the length of the bosses by around 15%.

In this embodiment the bimetal blade 84 and melting fuse 90, collectively the sensing means, are positioned 4mm above the central line 93 of the flange 2 and above the position of the electrical connections 91 and the lower fixing holes 87. In other embodiments it is envisaged that the sensing means 84 and 90, the electrical connecting means 91 and the lower fixing holes 87 may be repositioned so that the sensing means are below the central line. In embodiments where the sensing means 84 and 90 are above the central line of the flange 2 it may be necessary to lower the control and element assembly in the appliance so as to reduce the minimum water level.

In further embodiments the fixture of the control 81 to the element 23 may use means other than the three screws 79 and these may include :

a) Bayonet type fix of the control 81 into the jug body 30 that acts a clamping means. b) One centrally mounted bolt or screw type fixture.

c) One or two peripherally mounted bolt or screw type fixtures

d) Twist type connections mounted on the element 23 that would clamp the control 81 to the jug body 30. Examples of this twist type attachment are used to connect the main moulding to the chassis in the proprietor's X4 and Al series controls.

e) Click type fit.

f) A combination comprising any method from the above.

Sixth embodiment

It has been stated previously that a low position of the hot return 4 and a speedy response of the sensing means can both be beneficial in the design of water heating appliances. However it has been found, in some applications, that reducing the horizontal distance between the hot return 4 and the position the sheath 1 enters the flange 2 may slow down the speed in which one or more of the sensing means responds for example if the hot return is exposed above the water level. The sixth embodiment puts forward an assembly which enables the hot return 4 to be moved downwards towards the position the sheath 1 enters the flange 2 without adversely affecting the speed of response of the sensing means.

Figure 11a shows the dry side of the flange 2 which includes two bosses 6 centrally positioned at the top and the bottom of the flange 2. The dimple 5 and sheath 1 are positioned in close proximity to each other in the lower half of the flange 2.

In Figure l ib the cold tail area 9 is sectioned to illustrate an additional high conductive sleeve 15, made from, for example, copper positioned between the sheath 1 and the insulation means, for example, compressed magnesium oxide powder (not shown). The sleeve acts to transfer heat from the area of the heating wire 14 to the dry side of the flange 2. During normal running conditions the water in the appliance acts as a heat sink for the sheath 1 so that heat is not transferred into the flange 2 via the sleeve 15. However as the water level reduces around the hot return position 4 then the heat sink also reduces and the additional heat is transferred along the sleeve 15 into the dry side of the flange 2.

The heat transfer sleeve 15 may be formed as a tube or may be formed as one or more curved members of, for example, 120° and positioned at the top, bottom or side of the sheath, so as to optimise the heat transfer from the hot part of the sheath 1 to the dry side of the flange 2. The sleeve 15 may terminate immediately upon entering the flange 2 or may extend upwardly (not shown) closer to the position of the sensing means 84 and/or 90. Alternatively the sleeve 15 may connect onto a second heat transfer member (not shown) as it enters the flange so that the heat is transferred closer or adjacent to the sensing means 84 and/or 90. The sleeve 15 and the second transfer member may be attached by brazing, welding, leaser welding or interference fit. The second heat transfer member may be attached to the flange 2 by the same methods.

The sensing means 84 and 90 may be as illustrated in Figure 9a or may be of a different material or designs for example both the sensing means may be bimetals 84, or alternatively the melting fuse 90 may be a single push rod and positioned above or below the dimple, or one or more of the sensing means may be an electronic sensor, for example a Negative Temperature Coefficient (NTC) sensor.

Alternative Embodiments

Although the above embodiments have been described individually, those skilled in the art will appreciate that aspects of the above embodiments may be suitably combined. For example, as illustrated in Figure 10, an alternative embodiment may comprise the jug kettle of the first or second embodiment including the control and element assembly of the fourth and fifth embodiment. In the jug kettle embodiments described above, the moulded components are formed of plastic. As those skilled in the art will appreciate, this material is preferable for cost reasons. However, other suitable materials may instead be used for the moulded components.

In the heater element embodiments described above, the hot return is positioned above the position in which the sheath enters the flange, which results in a considerable reduction in cold pin length. As those skilled in the art will appreciate, as an alternative, a similar effect is achieved if the position of the hot return is level with or partially level with the position in which the sheath enters the flange, albeit to a lesser extent. Such an example is schematically illustrated in Figure 12, where the position of the hot return as indicated by the elongated dimple overlap with the positions where the sheath enters the flange.

Accordingly, the above embodiments illustrate, but do not limit, the present invention. Alternative embodiments which may occur to the skilled reader on reading the above description may also fall within the scope of the invention.

Claims

1. An immersed element cordless water heating appliance consisting of a heating element connected to an integrated control and four moulded components:

a body moulded component;

a lid moulded component for removable attachment to the body moulded component;

a switch actuator moulded component connected to the integrated control; and a base moulded component housing a cordless connector for electrical connection to the integrated control.

2. The appliance of claim 1 , wherein the body moulded component includes a spout portion, a handle portion, a reservoir portion, a steam tube portion, a control portion and a back cover portion.

3. The appliance of claim 2, wherein the handle portion has a C-shaped cross sectional profile.

4. The appliance of claim 1 , wherein the switch actuator moulded component is connected to the integrated control via a slot in the body moulded component.

5. An immersed element cordless water heating appliance consisting of a heating element connected to an integrated control and five moulded components:

a body moulded component;

a lid moulded component for removable attachment to the body moulded component;

a switch actuator moulded component connected to the integrated control;

a back cover moulded component including a handle and a slot for receiving the switch actuator moulded component; and

a base moulded component housing a cordless connector for electrical connection to the integrated control.

6. The appliance of claim 5 , wherein the body moulded component includes a spout portion, a reservoir portion, a steam tube portion and a control portion.

7. The appliance of claim 1 or claim 5, wherein the lid moulded component includes an integrally moulded mesh.

8. The appliance of claim 1 or claim 5, wherein the moulded components are arranged to be assembled together without additional fixing mechanisms. 9. The appliance of claim 8, wherein the moulded components are arranged to be assembled together by snap fittings.

10. The appliance of claim 1 or claim 5, wherein the heating element is connected to the integrated control by at least one screw and wherein the cordless connector is attached to the base moulded component by at least one screw.

1 1. The appliance of claim 8 or 9, wherein the heating element is connected to the integrated control without the use of screws. 12. The appliance of claim 5, wherein the body moulded component comprises a water window portion being formed from translucent or transparent plastic that is insert moulded into the body moulded component, and wherein the water window portion is partially covered by the back cover moulded component to form two water window portions.

13. The appliance of any preceding claim, wherein the size and profile of the components are minimised.

14. An immersed element cordless water heating appliance comprising:

a body;

a handle; and

a lid for removable attachment to the body; wherein the lid forms part of the handle when positioned on the body.

15. The appliance of claim 14, wherein the handle comprises a tubular horizontal portion and wherein the lid includes an elongate portion operable to close off the tubular horizontal portion of the handle.

16. The appliance of claim 14 or 15, wherein the lid includes an integrally moulded mesh filter. 17. An immersed element cordless water heating appliance comprising:

a heating element connected to an integrated control; and

a body for housing the heating element and integrated control, the body including a removable cover portion for allowing access to the integrated control when housed in the body;

wherein the removable cover portion is attachable to the integrated control by at least one screw, and

wherein the integrated control is attachable to the heating element by the same at least one screw. 18. A water heating appliance comprising:

a heating element connected to an integrated control;

a body housing the heating element and integrated control; and

a base component housing a cordless connector for electrical connection to the integrated control,

wherein the base component has a base footprint size smaller than the base footprint size of the body and wherein the vertical cross section of the body is adapted to form a sump around the base component.

19. An electrical appliance comprising:

an electrical component connected to an integrated control;

a body housing the electrical component and integrated control;

a secondary component attached to the body; and a base component housing a cordless connector for electrical connection to the integrated control,

wherein the base component has a base footprint size smaller than the base footprint size of the body such that the base component is able to fit within the secondary component.

20. The appliance of claim 19, wherein in use, the body of the appliance is directly supported by a surface when the base component is fitted within the secondary component.

21. The appliance of claim 19 or 20, wherein the secondary component is a back cover for the body and includes a handle portion.

22. An integrated control assembly for a water heating appliance, comprising a control element, bimetal primary protection and a melting fuse secondary protection that interfaces with a heating element of the water heating appliance,

wherein the heating element includes a sheath portion attachable to a flange of the water heating appliance and wherein a hot return portion of the heating element is positioned level with or above the point that the sheath enters the flange.

23. The integrated control assembly of claim 22 which is capable of handling 3000 watts.

24. The integrated control assembly of any one of claims 22 or 23, wherein the integrated control is fixed to the heating element by one or more of the following fixing methods: bayonet type fix, bolt or screw type fixture, twist type connection and click type fit.

25. The integrated control assembly of any one of claims 22 to 24, further comprising a seal provided between the heating element and the control element.

26. A heating element for a water heating appliance comprising a sheath portion attachable to a flange of the water heating appliance and a hot return portion positioned level with or above the point that the sheath enters the flange,

wherein the flange includes an elongate dimple along which the hot return is positioned.

27. The heating element of claim 26, wherein the element is made from a low conductive material. 28. The heating element of claim 27, wherein the element is made from stainless steel.

29. The heating element of any one of claims 26 to 28, wherein the elongate dimple has a length of between 5mm and 35mm.

30. The heating element of any one of claims 26 to 29, wherein the elongate dimple has a width of between 2mm and 10mm.

31. The heating element of any one of claims 26 to 30, wherein the elongate dimple has a depth of between lmm and 5mm.

32. The heating element of any one of claims 26 to 31, wherein the elongate dimple is facing in a direction towards a control element of the water heating appliance so as to form a recess for the hot return.

33. The heating element of any one of claims 26 to 31, wherein the elongate dimple is facing in a direction away from a control element of the water heating appliance so as to form an elongated platform for the hot return 34 The heating element of any one of claims 22 to 33, wherein the method of attaching at least one part of the sheath portion of the heating element to the flange of the heating element comprises of a laser welding process.

35. The heating element of any one of claims 26 to 34, wherein the element is capable of handling 3000 watts. 36. The heating element of any one of claims 26 to 35, further comprising a cold pin member which is positioned within an end portion of the sheath attached to the flange and extending from an electrical connection point through to a resistance wire which forms the heating part of the sheath. 37. The heating element of claim 36, wherein the cold pin member has a dimension between 5mm and 30mm long on the wet side.

38. The heating element of claim 37, wherein the length dimension is measured from the point on the wet side of the flange at which the sheath enters the flange to the end of the cold pin within the sheath.

39. A process of attaching a heating element in an immersed element water heating appliance, comprising attaching a sheath portion of the heating element to a flange of the water heating appliance by a laser welding process.

40. The process of claim 39, wherein the heating element is arranged such that a hot return portion of the heating element is positioned level with or above the point that the sheath enters the flange when the appliance is in use. 41. A heating element for a water heating appliance comprising a sheath portion attachable to a flange of the water heating appliance and a hot return portion positioned level with or above the point that the sheath enters the flange when the appliance is in use, wherein the heating element comprises a cold pin portion having a length of between 5mm and 30mm.

42. The heating element of claim 41 , wherein the length of the cold pin portion is 15mm.

43. A heating element of any previous claim further comprising a heat conductive sleeve is positioned in the element sheath in order to transfer heat from the region of the resistance wire of the element sheath towards the dry side of the element flange so as to influence the reaction time of the sensing means

44. The heating element of claim 43 wherein the heat conductive sleeve is tubular.

45. The heating element of claim 43 or 44, wherein the heat conductive sleeve comprises one or more circular shaped heat conductive members.

46. The heating element of any one of claims 43 to 45, wherein the heat conductive sleeve extends horizontally and/or vertically along the dry side of the flange. 47. The heating element of any one of claims 43 to 46, wherein the heat conductive sleeve extends in proximity to, or are in contact with the sensing means.

48. An integrated control assembly for a water heating appliance, comprising a control element, the heating element of any one of claims 41 to 47, and bimetal primary protection and a melting fuse secondary protection that interfaces with the heating element.

49. A method of manufacturing a connection between connecting points of an electrical appliance control element and a cordless connector, comprising coating one or both of the connecting points with a material having a low melting point that melts to form a low resistant connection.

50. The method of claim 49, wherein the material has a melting point of between 225° and 325°.

51. The method of claim 50, wherein the material is tin or tin alloy.

52. The method of claim 49, wherein the material is an eutectic alloy.

53. The method of any one of claims 49 to 52, wherein the coating thickness is between 1 and 15 microns.

54. A safety switch mechanism for a water heating appliance, comprising:

switch means for connecting and disconnecting power from a control means; a first switch actuator;

a second switch actuator;

an intermediate switch actuator for engagement with the first switch actuator, the second switch actuators and the switch means,

wherein the intermediate switch actuator is operable to pivot about a pivot point and to engage and disengage with the switch means in response to a first force applied from the first switch actuator at one end of the intermediate switch actuator and independently in response to a second force applied from the second switch actuator.

55. The safety switch mechanism of claim 47, wherein the intermediate switch actuator and second switch actuator are arranged to act independently on the switch means.

56. The safety switch mechanism of claim 54 or 55, wherein the first switch actuator comprises a dry boil push rod.

57. The safety switch mechanism of claim 54 or 55, wherein the second switch actuator comprises a steam switch actuator.

58. A water heating appliance as set out in any one of claims 1 to 21 with a control assembly of any one of claims 22 to 25 and 48. 59. A water heating appliance as set out in any one of claims 1 to 21 with a heating element of any one of claims 26 to 38 and 41 to 47.

60. A water heating appliance with a control assembly of any one of claims 22 to 25 and 41 and a heating element of any one of claims 26 to 38 and 41 to 47.

61. The water heating appliance of any one of claims 58 to 60 further comprising the safety switch mechanism of any one of claims 54 to 57.

62. A water heating appliance substantially as hereinbefore described with reference to, or as illustrated in Figure 3a, 3b, 3c, 3e, 5a, 5b, 5c, 5e or 10 of the accompanying drawings.

63. A heater element for a water heating appliance substantially as hereinbefore described with reference to, or as illustrated in Figure 7c, 7f or 8a and 8b of the accompanying drawings.

64. A heater element and control assembly substantially as hereinbefore described with reference to, or as illustrated in Figure 3b, 5b, or 8a and 8b of the accompanying drawings.

65. An integrated control substantially as hereinbefore described with reference to, or as illustrated in Figure 9a and 9b of the accompanying drawings

66. A safety switch mechanism substantially as hereinbefore described with reference to, or as illustrated in Figure 9c of the accompanying drawings.