Control assembly for cordless liquid heating appliance

Abstract

A control assembly for a cordless liquid heating appliance. The control assembly comprises a cordless base connector for mounting to the cordless power base and an adapter (8) for mounting to the liquid heating container. The adapter (8) comprises a pin (54) comprising first and second electrical contacts (56, 58) arranged to connect with corresponding first and second electrical contacts in the cordless base connector. The adapter (8) further comprises a third electrical contact (62) having an annular form extending around the pin (54) and arranged to connect with a corresponding third electrical contact in the cordless base connector. The adapter (8) also includes a fourth electrical contact (64) having an annular form extending around the third electrical contact (62) and arranged to connect with a corresponding fourth electrical contact in the base connector. Third and fourth electrical contacts (62, 64) and corresponding third and fourth electrical contacts are configured to provide live and neutral connections to the liquid heating container.

Description

TECHNICAL FIELD

[0001] The present invention relates to a control assembly for a cordless liquid heating appliance, a support structure forming part of such a control assembly and a method of manufacturing at least an adapter of such a control assembly. BACKGROUND

[0002] Cordless liquid heating appliances generally comprise a liquid heating vessel which can be seated on a cordless power base. Such cordless liquid heating appliances generally comprise a control assembly comprising an adapter arranged in the liquid heating vessel and a cordless base connector arranged in the cordless power base. When the liquid heating vessel is seated on the cordless power base, the adapter and the cordless base connector cooperate together to facilitate the transfer of power and / or data between the liquid heating vessel and the cordless power base. Two main types of control assembly in use include 3-pole and 5-pole assemblies. 3-pole assemblies generally provide live, neutral and earth connections, whereas 5-pole assemblies generally provide live, neutral, earth and data connections (using two poles of the assembly).

[0003] The control assemblies discussed above generally take the form of a 360° assembly, such that the liquid heating vessel can be placed on the cordless power base in any angular position. In order to facilitate such an arrangement, the adapters in the prior art generally comprise a central contact pin surrounded by a number of radially spaced annular contacts. The adapters of 3-pole assemblies comprise a central pin surrounded by a first annular contact radially spaced from the pin and a second annular contact radially spaced from the first annular contact. 5-pole adapters generally comprise the same pin, first and second annular contacts as the 3-pole adapters, and two further annular contacts each radially spaced from the first and second annular contacts. In such 5-pole adapters, the width of the adapter can become relatively large due to the need to provide sufficient space between each of the contacts. As a result, the support structure supporting the contacts of the adapter can be relatively wide. The relatively large width of the support structure can mean that the support structure, and therefore the adapter, has an increased manufacturing cost. SUMMARY

[0004] The present invention aims to address or at least mitigate at least one of the above outlined problems and, when viewed from a first aspect, provides a control assembly for a cordless liquid heating appliance comprising a liquid heating vessel and a cordless power base, the control assembly comprising: a cordless base connector for mounting to the cordless power base; and an adapter for mounting to the liquid heating vessel, the adapter being configured to cooperate with the cordless base connector when the liquid heating vessel is seated on the cordless power base, wherein the adapter comprises: a pin post, the pin post comprising a first electrical contact and a second electrical contact, the first electrical contact and the second electrical contact arranged to connect with a corresponding first electrical contact and a corresponding second electrical contact in the cordless base connector; a third electrical contact, the third electrical contact having an annular form extending around the pin post and radially displaced from the pin post, and arranged to connect with a corresponding third electrical contact in the cordless base connector; and a fourth electrical contact, the fourth electrical contact having an annular form extending around the third electrical contact and radially displaced from the third electrical contact, and arranged to connect with a corresponding fourth electrical contact in the cordless base connector; wherein the third electrical contact and the fourth electrical contact in the adapter and the corresponding third electrical contact and the corresponding fourth electrical contact in the cordless base connector are configured to provide a live connection and a neutral connection to the liquid heating vessel.

[0005] In comparison to prior art control assemblies using a pin post with a single electrical contact, the control assembly according to the present application uses a pin post with both a first electrical contact and a second electrical contact. The applicant has recognised that by including an additional electrical contact with the pin post, the number of, for example, annular contacts radially displaced around the pin post can be reduced. As a result, the radial length of the outermost electrical contact of the adapter, and therefore the corresponding electrical contact in the cordless base connector, can be reduced in comparison to prior art control assemblies. This can reduce the overall footprint of the adapter and the cordless base connector.

[0006] In addition to the above, by incorporating a second electrical contact with the pin post, one of the annular contacts that would otherwise surround the pin post can be removed when compared to a typical prior art control assembly. As will be understood by the skilled person, the amount of material required to form a contact on a pin post can be significantly less than the amount of material required to form such an annular contact. As a result, the control assembly according to the present application can be formed using less material to form the electrical contacts. As the contacts are typically made from silver plated copper or a copper alloy, this can mean a significant reduction in the manufacturing cost of the control assembly.

[0007] Furthermore, in the control assembly according to the application, the third and fourth annular electrical contacts and the corresponding third and fourth electrical contacts in the cordless base connector are configured to provide live and neutral connections to the liquid heating vessel. In this way, one of the third and fourth annular contacts can be considered as a live contact, and the other one of the third and fourth annular contacts can be considered as a neutral contact. The same applies to the corresponding third and fourth electrical contacts in the cordless base connector. The applicant has realized that the use of the third and fourth annular electrical contacts to provide live and neutral connections is advantageous over the use of the first and second contacts which form part of the pin. In particular, as the first and second contacts on the pin can be relatively close together as they form part of a single pin, the use of such contacts as live and neutral contacts can result in arcing and tracking problems. In contrast, the use of the third and fourth annular electrical contacts can advantageously avoid such arcing and tracking problems. When the adapter is mounted to the liquid heating vessel, the third and fourth electrical contacts can be connected to powered components within the liquid heating appliance, such as a heating element. Similarly, when the cordless base connector is mounted to the cordless power base, the corresponding third and fourth electrical contacts can be connected to live and neutral power sources within the cordless power base.

[0008] The adapter described above can be considered as a cordless adapter. Similarly, as each of the adapter and the cordless base connector comprises electrical contacts, the adapter can be considered as an electrical adapter, such as a cordless electrical adapter, and the cordless base connector can be considered as a cordless base electrical connector.

[0009] In some countries, no ground connection is required for the liquid heating vessel to be set up. Thus, the control assembly described above can comprise sufficient contacts to facilitate proper functioning of the liquid heating vessel. However, in other countries, the presence of a ground contact is necessary to meet standard requirements. Thus, in some embodiments, the adapter further comprises a fifth electrical contact, radially displaced from the pin post and arranged to connect with a corresponding fifth electrical contact in the cordless base connector, and wherein the fifth electrical contact is configured to provide a ground connection to the liquid heating vessel. Thus, such a control assembly provides a ground connection for the liquid heating vessel in these required countries. The fifth electrical contact can be arranged in any suitable position within the adapter, and similarly, the corresponding fifth electrical contact can be arranged in any suitable position in the cordless base connector. However, in a set of embodiments, the fifth electrical contact is radially outwardly displaced from the fourth electrical contact. The fifth electrical contact providing the ground connection can thus be the most radially outward contact. In the case that the fifth electrical contact is the most radially outward contact and has an annular form, the fifth electrical contact can be the largest of all the contacts. In such an instance, having the fifth electrical contact as the ground contact can again reduce the material cost in the control assembly, as the ground contact can be made of brass, which is cheaper than the silver-plated copper that can be used for the live and neutral contacts. As the ground contact is only used in fault situations, and does not switch current, it does not need to be silver-plated.

[0010] The fifth electrical contact and the corresponding fifth electrical contact can have any suitable form. In a set of embodiments, the fifth electrical contact has an annular form. In such embodiments, the corresponding fifth electrical contact can be a point-like contact. In other embodiments, the fifth electrical contact is a point-like contact, and wherein the corresponding fifth electrical contact has an annular form. In the case of a point-like contact, this is intended to mean that the respective contact extends around the connector or adapter to a limited angular range. Thus, the point-like contact only contacts a limited angular portion of the annular form of the contact it is contacting. Nonetheless, providing one contact with an annular form and a point-like contact can facilitate connection between them without having to consider the angular orientation in which the connector and adapter are mated. The corresponding first, second, third, and fourth contacts in the cordless base connector can also be point-like contacts. Using an annular contact that mates with a point-like contact can reduce the total amount of material required to provide the electrical connection, at least when compared to two contacts having a given annular form.

[0011] The third electrical contact, the fourth electrical contact, and the fifth electrical contact (where provided) can all extend around a common central axis. In other words, they can be coaxial. The central axis can be the central axis extending through the pin post (e.g. the centre of the pin post).

[0012] The first and second electrical contacts in the adapter can be used for any suitable purpose. For example, in addition to the third and fourth electrical contacts, the first and second electrical contacts can also be used for power transmission, but at a different voltage than the power transmission via the third and fourth electrical contacts. For example, the first and second electrical contacts can be used for transmitting power at a voltage of 12 V, for example to a pump inside the liquid heating vessel. However, in a set of embodiments, the first and second electrical contacts in the adapter and the corresponding first and second electrical contacts in the cordless power base together provide a signal connection for transmitting data between the adapter and the cordless base connector. Thus, the first electrical contact can be considered a first signal contact, and the second electrical contact can be considered a second signal contact. The data transmission via the first and second electrical contacts and the corresponding first and second electrical contacts can use only a relatively low current and / or potential difference. In this way, despite the first and second electrical contacts being arranged together on the pin post, the risk of arcing can be relatively low.

[0013] The first and second electrical contacts can provide any suitable data transmission. For example, the cordless power base can comprise a controller, and the liquid heating vessel can comprise electronic components, for example a temperature sensor. The first and second electrical contacts and the corresponding first and second electrical contacts can thus facilitate data transmission between the electronic components in the liquid heating vessel and the controller in the cordless power base.

[0014] In a set of embodiments, the adapter forms part of a control device for mounting to the liquid heating vessel. In some embodiments, the adapter can be integrally formed with or attached to the control device. The control device can comprise means for at least partially controlling operation of the liquid heating vessel. The control device can comprise at least one temperature monitoring device arranged to monitor a temperature of the liquid heating vessel, for example a temperature of a base of a heating chamber of the liquid heating vessel. The temperature monitoring device can for example comprise a thermally sensitive actuator configured to operate a switch at a predetermined temperature. The switch can be arranged to cut off a supply of power to the liquid heating vessel, for example to a heating element therein.

[0015] In yet another set of embodiments, the control device comprises electronic components to which the first and second electrical contacts of the pin post are electrically connected. Thus, the first and second electrical contacts can facilitate power and / or data transmission between the electronic components and another component arranged in the cordless power base.

[0016] The electronic components can be arranged on the control device in any suitable manner. For example, the electronic components can be mounted to the upper side of the control device and connected to the first and second electrical contacts by corresponding electrical wires. In another set of embodiments, the control device comprises a support extending away from the center of the control device, and wherein the electronic components are mounted to the end of the support. Such an arrangement can be particularly suitable when it is not desirable or necessary to mount the electronic components near the center of the control device.

[0017] In another set of embodiments, the pin and the electronic components are formed as a module that is inserted into the adapter. The module can comprise a mounting body to which the components of the pin and the electronic components can be mounted. For example, the first and second contacts can be mounted to the mounting body and electrically connected to the electronic components, which can also be mounted to the mounting body. In some embodiments, the mounting body can comprise mounting features for securing the electronic components in place on the mounting body. The mounting body can comprise a pin-shaped portion configured to receive the first and second electrical contacts. The pin-shaped portion can comprise a hollow core shaped to receive the first electrical contact therein. The second electrical contact can be arranged on the outer surface of the pin-shaped portion. The material of the pin-shaped portion can serve to electrically insulate the first and second contacts. The mounting body can be made of an electrically insulating material. Providing the electronic components and the pin together as a module can allow the pin and the electronic components to be easily inserted into and mounted within the control assembly.

[0018] The electronic components of any of the above embodiments can comprise any suitable electronic components. In one set of embodiments, the electronic components comprise a temperature sensor. The temperature sensor may, for example, comprise a thermistor, such as a negative temperature coefficient (NTC) thermistor. In embodiments in which the electronic components and the contact pin are formed as part of a module, the electronic components are a temperature sensor, which can ensure consistent and proper positioning of the temperature sensor. Of course, the electronic components can comprise any other suitable electronic components. For example, the electronic components can comprise a motor, a solenoid, a relay, or a display.

[0019] The third and fourth electrical contacts that provide the live and neutral connections for the liquid heating vessel can be spaced apart from one another by an air gap sufficient to minimize the likelihood of an electrical arc occurring between the two contacts. However, the Applicant has recognized that spacing the third and fourth electrical contacts with an air gap can increase the overall size of the adaptor. Accordingly, in one set of embodiments, the third and fourth electrical contacts are separated by an annular insulating member, with the third electrical contact in contact with an inwardly facing surface of the annular insulating member, and with the fourth electrical contact in contact with an outwardly facing surface of the annular insulating member. The Applicant has realized that the use of an insulating member, i.e. a body of material, can allow the third and fourth electrical contacts to be positioned closer to one another relative to spacing the third and fourth electrical contacts with air. In other words, the thickness of the insulating member can be less than the air gap required to properly space the third and fourth electrical contacts apart. The use of an insulating member can therefore further reduce the footprint of the adaptor and cordless base connector. In other embodiments, the third and fourth electrical contacts can be separated by an annular insulating member, but not necessarily in contact with the inwardly and outwardly facing surfaces. Instead, the third electrical contact can be disposed on a first side of the annular insulating member, and the fourth electrical contact can be disposed on an opposite side of the annular insulating member. Nonetheless, such an arrangement can use less space than spacing the contacts apart by air alone.

[0020] In yet another set of embodiments, the adaptor includes an axis extending through the contact pin post, and wherein the insulating member extends to a greater axial length than the third and fourth electrical contacts in a direction towards the exposed end of the contact pin post. The insulating member thus extends further in practice than the third and fourth electrical contacts, increasing the distance in the free space between the third and fourth electrical contacts. This can further minimize the risk of an electrical arc occurring between the third and fourth electrical contacts.

[0021] In embodiments including a control device, the control device can include a support structure, the pin post and the third and fourth (and fifth, if provided) electrical contacts are mounted to the support structure, and the annular insulating member can be integrally formed with the support structure. The support structure can be formed of injection molded plastic.

[0022] The first and second electrical contacts can be provided on the pin post in any suitable manner. In one set of embodiments, the pin post includes an insulating member disposed between the first and second electrical contacts. The insulating member can serve to electrically isolate each of the first and second electrical contacts from one another. The insulating member can have any suitable form, which can depend on the relative arrangement of the first and second electrical contacts on the pin post. In embodiments in which the contact pin post and electronic components are provided as a module, the insulating member can be provided by a mounting body of the module. The first and second electrical contacts can be mounted to the mounting body.

[0023] The first and second electrical contacts can be isolated from one another in any suitable arrangement. In one set of embodiments, the first and second electrical contacts are separated from one another along the axis of the pin post. With the first and second electrical contacts separated from one another, they can be considered to be electrically separated, i.e. isolated, from one another. Separating the first and second electrical contacts along the axis of the pin post can advantageously allow the first and second electrical contacts to mate with corresponding first and second electrical contacts in a cordless base connector without having to account for the angular orientation in which the adapter is placed on the cordless base connector. The corresponding first and second electrical contacts in the cordless base connector can be of a suitable form so as to contact the first and second electrical contacts when the adapter and the cordless base connector are mated together. Each of the first and second electrical contacts can extend around the entire pin post, e.g. around its entire circumference. In some embodiments, the first electrical contact protrudes from an end of the pin post and the second electrical contact extends around the circumference of the pin post.

[0024] In some embodiments, the first and second electrical contacts are separated from one another about the axis of the pin post. Separating the first and second electrical contacts about the axis of the pin post can provide another approach for electrically isolating the first and second electrical contacts from one another. Again, this can still facilitate mating of the first and second electrical contacts with corresponding first and second electrical contacts in a cordless power base without having to account for the angular orientation in which the adapter is placed on the cordless power base.

[0025] The pin post can have any suitable cross-sectional shape. In one set of embodiments, the pin post has a substantially cylindrical shape. A pin post having a substantially cylindrical, e.g. cylindrical, shape can advantageously facilitate positioning of the adapter in any angular position on the cordless base connector. In some embodiments, the end of the pin post can be pointed. A pointed end can again facilitate placement of the adapter on the cordless base connector.

[0026] In some embodiments, the control assembly is a 360° cordless control assembly. A 360° cordless control assembly can advantageously allow the adapter (and hence the liquid heating vessel to which the adapter is secured) to be placed on the cordless base connector (and cordless power base) in any angular orientation. This can improve ease of use of the appliance. Thus, the adapter can be a 360° adapter and the cordless base connector can be a 360° cordless base connector. Each of such an adapter and cordless base connector can be substantially cylindrical in shape, e.g. cylindrical, which can facilitate mating in any angular orientation.

[0027] In some embodiments, the pin post is arranged centrally of the adapter. Having the pin post arranged centrally of the adapter can again improve ease of use when the assembly is mounted to a liquid heating vessel and a cordless power base.

[0028] The invention extends to a cordless liquid heating appliance comprising a control assembly. Thus, when viewed from a second aspect, there is provided a cordless liquid heating appliance comprising: a cordless power base for connection to a mains electricity supply; a liquid heating vessel, the liquid heating vessel being configured to be seated on the cordless power base; and a control assembly according to any of the preceding aspects or embodiments, wherein the adapter is mounted to the liquid heating vessel, and wherein the cordless base connector is mounted to the cordless power base.

[0029] In the case of being configured to be seated on the cordless power base, this is intended to mean that the liquid heating vessel can be lifted away from the cordless power base, and seated back on the cordless power base. Due to the control assembly can have a smaller length, the size of the liquid heating vessel and / or the cordless power base can be reduced compared to the prior art.

[0030] In yet another set of embodiments, the liquid heating vessel comprises a chamber for receiving a volume of liquid to be heated and a heating element for heating the liquid within the vessel, and wherein the third and fourth electrical contacts are electrically connected to the heating element. The cordless power base can comprise a power cable adapted to be connected to a mains electricity supply, and wherein the corresponding third and fourth electrical contacts can be connected to the live and neutral connections of the power cable. Of course, the liquid heating vessel can comprise any other suitable powered component, such as a motor, a relay, a solenoid, a display, etc., and the third and fourth electrical contacts can be electrically connected to such components.

[0031] The liquid heating vessel can comprise a first electronic component to which the first and second contacts of the adapter are connected, and the cordless power base comprises a second electronic component to which the corresponding first and second contacts of the cordless base connector are connected. The first and second electrical contacts and their corresponding first and second electrical contacts can thus provide an electrical connection between the first and second electronic components. The first electronic component can comprise: a temperature sensor, a motor, etc. The second electronic component can comprise an electronic controller. The first and second electrical contacts and the corresponding first and second electrical contacts can thus facilitate data transfer between the first and second electronic components.

[0032] As described in the background section above, 3-pole and 5-pole control assemblies are known in the art. The adapters and cordless base connectors of such control assemblies each comprise a support structure with each of the electrical contacts. In the prior art control assemblies, different support structures have to be formed for 3-pole and 5-pole control assemblies. The applicant has recognised that it can be inefficient to produce separate support structures for different types of control assemblies. Accordingly, when viewed from a third aspect, the present application provides a support structure for forming at least part of an adapter configured to provide an electrical connection with a corresponding cordless base connector, the support structure comprising: a pin post receiving portion capable of receiving a plurality of different types of pin posts, the pin posts comprising at least a first pin post with a first electrical contact and a second pin post with a first electrical contact and a second electrical contact; a first annular contact receiving portion capable of receiving a third electrical contact having an annular form; a second annular contact receiving portion capable of receiving a fourth electrical contact having an annular form; and a third receiving portion capable of receiving a fifth electrical contact.

[0033] Accordingly, the applicant has recognised that a single support structure can be used to form a variety of different adapters depending on which pin post is inserted into the structure and / or which of the third, fourth and fifth electrical contacts are received in the support structure. The pin post receiving portion capable of receiving a plurality of different types of pin posts is intended to mean that a number of different pin posts can be inserted into the pin post receiving portion interchangeably, but only a single pin post is received therein at any given time.

[0034] For example, a first pin post with a first electrical contact can be inserted into the pin post receiving portion, a third electrical contact can be inserted into the first annular contact receiving portion, and a fourth electrical contact can be inserted into the second annular contact receiving portion, thereby forming a 3-pole adapter. In contrast, a 5-pole adapter can be formed by placing a second pin post carrying a first electrical contact and a second electrical contact into the pin post receiving portion, placing a third electrical contact into the first annular contact receiving portion, placing a fourth electrical contact in the second annular contact receiving portion and placing a fifth electrical contact in the third receiving portion.

[0035] The receiving portions can have any suitable form / shape so as to be suitable for receiving their respective contacts. In one set of embodiments, the pin-receiving portions comprise apertures extending through the support structure into which the pins can be inserted. The pin-receiving portions can comprise retention features configured to engage with the pins or with members to which they are connected so as to properly secure the pins in place. The first, second and third ring-shaped contact-receiving portions can each comprise a structure which can have a corresponding ring-shaped form. For example, each of such portions can comprise a ring-shaped wall onto which the respective electrical contact can be mounted. Each of such portions can also, or instead, comprise an aperture extending into the support structure and shaped to receive a protrusion or tab extending from the respective electrical contact. Such apertures can serve at least to locate the respective electrical contact.

[0036] In one set of embodiments, the first, second and third ring-shaped contact-receiving portions are radially displaced from one another relative to the pin-receiving portions. Radially displacing the first, second and third ring-shaped contact-receiving portions can properly space the respective electrical contacts within the support structure, when they are mounted to the support structure, so that each of the contacts is electrically isolated from one another.

[0037] In another set of embodiments, the support structure comprises only the pin-receiving portions, the first, second and third ring-shaped receiving portions for receiving electrical contacts. The electrical contacts are those suitable for connection with corresponding electrical contacts in a cordless base connector which can be mated to the adaptor. According to such embodiments, the support structure can only be able to receive up to five electrical contacts (assuming that the pins can carry up to two electrical contacts).

[0038] The support structure can have any suitable form and be formed from any suitable material. In one set of embodiments, the support structure is formed from a plastic body. For example, the support structure can comprise an injection moulded plastic body. In some embodiments, the third receiving portion can be able to receive a fifth electrical contact having a ring-shaped form.

[0039] Applicants have recognised that, by using the support structures described above, new methods of manufacturing / assembly of the adaptor can be employed. Thus, when viewed from a fourth aspect, there is provided a method of forming at least one adaptor of a control assembly, the adaptor being configured for mounting to a liquid heating vessel, the method comprising the steps of: forming a support structure according to any of the embodiments described above; determining whether a pin is required and, if so, when; selecting one of a first pin carrying a first electrical contact and a second pin carrying a first electrical contact and a second electrical contact; and inserting a selected pin into the pin receiving portion; inserting a third electrical contact having a ring form into the first ring contact receiving portion; and inserting a fourth electrical contact having a ring form into the second ring contact receiving portion.

[0040] The use of the above support structure and method can advantageously allow for the quick and easy manufacturing and assembly of a number of different adapters.

[0041] In some countries no ground connection can be required. In such cases it can be determined that no pin is required. In this case, when it is determined that no pin is required, no pin is inserted into the support structure. In this way, only the further steps of inserting the third and fourth electrical contacts into the support structure can be performed. This can form a 2-pole adapter. There can be cases where a pin is always required, for example in order to meet certain electrical standards. Therefore, the step of determining whether a pin is required can be omitted. Nonetheless, the steps of selecting and inserting a selected pin can still be included.

[0042] When a pin is required and a first pin is selected, for example because the adapter is not required to be able to facilitate data transfer, the method forms a 3-pole adapter. In contrast, in the case where a second pin is selected and inserted into the pin receiving portion, the method forms a 4-pole adapter. The third electrical contact and the fourth electrical contact can be used to provide live and neutral connections. When the first pin is selected, the first electrical contact can be used to provide a ground connection, whereas when the second pin is selected, the first and second contacts can be used to provide a data connection.

[0043] In yet another set of embodiments, the method further comprises inserting a fifth electrical contact into the third receiving portion. In the case where a second pin comprising first and second electrical contacts is selected and inserted, such embodiments form a 5-pole adapter. The fifth electrical contact can be used to provide a ground connection to a liquid heating vessel in which the adapter is installed.

[0044] In a set of embodiments, the second pin with the first electrical contact and the second electrical contact is part of a module comprising the second pin and integrated electronic components electrically connected to the first and second electrical contacts of the second pin. Such a pin module can simplify the assembly process, as the pin, the contacts and the integrated electronic components can be quickly and easily inserted into the support structure.

[0045] The applicant has recognised that the above advantages are not necessarily limited to the formation of an adapter. Therefore, when viewed from a further aspect, there is provided a connector support structure for forming at least part of a configuration of a cordless base connector configured to provide an electrical connection with a corresponding adapter, the support structure comprising: a first contact receiving portion configured to receive a first corresponding electrical contact, a second contact receiving portion configured to receive a second corresponding electrical contact, a third contact receiving portion configured to receive a third corresponding electrical contact, a fourth contact receiving portion configured to receive a fourth corresponding electrical contact, and a fifth contact receiving portion configured to receive a fifth corresponding electrical contact.

[0046] Thus, the connector support structure can be capable of receiving up to five electrical contacts. Any number of electrical contacts can be mounted to the connector support structure, thereby forming a desired cordless base connector.

[0047] In some embodiments, the support structure comprises a centrally arranged cylindrical boss having a hollow core and an annular wall spaced apart from and surrounding the cylindrical boss to define an annular cavity between the cylindrical boss and the annular wall, wherein the first and second contact receiving portions are arranged within the hollow core in the cylindrical boss, wherein the second and third contact receiving portions are arranged at a base of the hollow core, and wherein the fifth contact receiving portion is arranged in an outwardly facing surface of the annular wall. Thus, the various contact receiving portions can be suitably arranged to position the contacts to cooperate with corresponding contacts in an adaptor.

[0048] The support structure can be formed from a plastics material. The support structure can be injection moulded.

[0049] According to a further aspect of the present application, there is provided a method of forming a cordless base connector of a control assembly, the cordless base connector being configured to be mounted in a cordless electrical power base, the method comprising the steps of: forming a connector support structure according to any of the above embodiments; determining how many electrical contacts are required within the cordless base connector; inserting at least two of the first, second, third, fourth and fifth corresponding electrical contacts into the respective first, second, third, fourth and fifth contact receiving portions.

[0050] Thus, a single connector support structure can be used to form a number of different cordless base connectors. The number of components required to manufacture different cordless base connectors can therefore be reduced.

[0051] According to a further aspect of the present application, there is provided a control assembly for a cordless liquid heating appliance comprising a liquid heating vessel and a cordless electrical power base, the control assembly comprising: a cordless base connector for mounting to the cordless electrical power base; and an adaptor, the adaptor forming part of a control device for mounting to the liquid heating vessel, wherein the adaptor is configured to cooperate with the cordless base connector when the liquid heating vessel is seated on the cordless electrical power base, and wherein the adaptor comprises: a pin post, the pin post comprising a first electrical contact and a second electrical contact, the first electrical contact and the second electrical contact arranged to connect with corresponding first and second electrical contacts in the cordless base connector; a third electrical contact, the third electrical contact having an annular form extending around and radially displaced from the pin post, and arranged to connect with a corresponding third electrical contact in the cordless base connector; and a fourth electrical contact, the fourth electrical contact having an annular form extending around and radially displaced from the third electrical contact, and arranged to connect with a corresponding fourth electrical contact in the cordless base connector; wherein the third and fourth electrical contacts in the adapter and the corresponding third and fourth electrical contacts in the cordless base connector are configured to provide live and neutral connections to the liquid heating vessel.

[0052] Any features of embodiments of the previous aspects of the application can equally apply to the above aspects of the application.

[0053] In any of the above aspects or embodiments, the liquid heating vessel can be suitable for heating any suitable liquid, such as water, milk, tea, coffee, etc. The liquid heating appliance of any of the above embodiments can be a domestic countertop liquid heating appliance, such as in the form of a kettle, coffee maker, milk frother, etc. BRIEF DESCRIPTION OF DRAWINGS

[0054] Some preferred embodiments of the application will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a schematic view of a cordless liquid heating appliance according to an embodiment of the application; Figure 2 is a perspective view of a control assembly according to an embodiment of the application; Figure 3 is a perspective view of the control device shown in Figure 2 is a perspective view of the underside of the control device shown in Figure 4 is a cross-sectional view through Figure 2 the control device shown in Figure 5 is a view of the support structure of the control device shown in Figure 2 is a perspective view of the underside of the support structure shown in Figure 6 Figure 5 is a perspective view of the underside of the support structure shown in Figure 7 is a plan view of the underside of the support structure shown in Figure 5 is a plan view of the top side of the support structure shown in Figure 8 Figure 5 is a plan view of the top side of the support structure shown in ​​Figure 9 is a cross-sectional view of the support structure shown in Figure 5 Figure 10 is Figure 2 is a perspective view of the control device shown in Figure 11 is a view of a module including a pin post and electronic components according to one embodiment of the present application; Figure 12 is a cross-sectional view of the module shown in Figure 11 Figure 13 is Figure 11 is a perspective view of the mounting body of the module shown in Figure 14 is a perspective view of the second electrical contact shown in the previous figure; Figure 15 is a perspective view of the first electrical contact shown in the previous figure; Figure 16 is Figure 2 is a perspective view of the cordless base connector shown in Figure 17 is a cross-sectional view through the cordless base connector showing the corresponding first and second electrical contacts; Figure 18 is a perspective view of a control device according to another embodiment of the present application; Figure 19 is a perspective view of a control device according to yet another embodiment of the present application; Figure 20 is Figure 18 is a view of the control device shown in Figure 21 is Figure 18 is another view of the bottom side of the control device shown in Figure 22 is a view of a control assembly according to another embodiment of the present application, wherein its adapter is a 3-pole adapter; Figure 23 is Figure 22 is a view of the bottom side of the control device shown in Figure 24 shows a view of the control device, wherein its components are hidden to show the electrical connections within the control device; Figure 25 is a perspective view of a 3-pole cordless base connector; Figure 26 ​​shows a perspective view of a pin post of an adapter according to another embodiment of the application; and Figure 27 shows a flow chart illustrating a method of forming an adapter according to one embodiment of the application. DETAILED DESCRIPTION

[0055] Figure 1 is a schematic view of a cordless liquid heating appliance 2 according to one embodiment of the application. The cordless liquid heating appliance 2 comprises a liquid heating vessel 4 and a cordless power base 6. The liquid heating vessel 4 comprises an adapter 8 and the cordless power base comprises a cordless base connector 10 (hereinafter referred to as "the connector 10"). The adapter 8 and the connector 10 together form a control assembly 13 according to one embodiment of the application. In the embodiment shown, the adapter 8 is attached to and forms part of a control device 12 which is mounted within the liquid heating vessel 4. The liquid heating vessel comprises a heated base 14 which is heated by a heating element 16. The heated base 14 at least partially defines a chamber 20 in which liquid (e.g. water) is received and heated during operation of the appliance 2. The cordless power base 6 comprises a power cord 18 which can be connected to a suitable power source, such as a mains electricity supply (not shown). The power cord 18 can be electrically connected to suitable components within the cordless power base 6 and can be directly or indirectly electrically connected to the connector 10 which is provided with suitable components.

[0056] Figure 2 shows a perspective view of a control assembly 13 according to one embodiment of the application. The control assembly 13 comprises a cordless base connector 10 for mounting to a cordless power base 6 and an adapter 8 for mounting to a liquid heating vessel 4. In the embodiment shown, the control assembly 13 takes the form of a 5-pole control assembly 13. In other words, each of the adapter 8 and the connector 10 comprises five electrical contacts.

[0057] In the embodiment shown, the adapter 8 is provided with the control device 12. The control device 12 comprises a support structure 22 in which the adapter 8 is formed. The support structure 22 can be formed from injection moulded plastic. A metal plate 24 can be attached to the top of the support structure 22 in order to support further components. The control device 12 comprises a number of thermally sensitive actuators 26 which can be arranged to monitor the temperature of components (e.g. the heating element 16) within the liquid heating vessel 4. When a predetermined temperature is detected, the thermally sensitive actuators 26 can be used to break an electrical circuit (not visible) within the control device 12.

[0058] A module 28 comprising a temperature sensor 30 is also mounted within the control device 12. The module 28 is mounted such that the temperature sensor 30 is in a fixed position with respect to the support structure 22 of the control device 12. As shown in Figure 2, the temperature sensor 30 is arranged to monitor the temperature of the liquid within the chamber 20 of the liquid heating vessel 4.Figure 2 As can be seen, the control device 12 includes a first electrical tab 32 and a second electrical tab 34. Although not visible in this view, each of these first and second electrical tabs 32, 34 can be connected to a corresponding one of the third and fourth electrical contacts within the adapter 8. These contacts can be connected to the electrical power source within the adapter 8, as will be described in more detail below. Figure 3 As can be seen, the first and second electrical tabs 32, 34 can be connected to components within the liquid heating vessel 4 that are to be powered, such as the heating element 16.

[0059] The connector 10 includes a connector support structure 36 to which a number of corresponding electrical contacts are mounted. The connector support structure 36 defines a central boss 38 having an opening 40 therein. The connector support structure 36 also includes a surrounding annular wall 42 spaced apart from the central boss 38, which defines an annular aperture 44. Although not visible, corresponding first and second electrical contacts are disposed within the cylindrical opening 40, a third corresponding electrical contact 46 and a fourth corresponding electrical contact 48 are disposed in the annular aperture 44, and a fifth corresponding electrical contact 50 is disposed on an outermost wall 52 of the connector support structure 36.

[0060] More details of the adapter 8 will now be described. Figure 3 A perspective view of the bottom side of the control device 12 is shown in Figure 2 As can be more clearly seen in this view, the adapter 8 is included. As can be seen in this view, in some embodiments, the adapter 8 includes a pin post 54. The pin post includes a first electrical contact 56 and a second electrical contact 58. The first electrical contact 56 extends from an end of the pin post 54, and the second electrical contact 58 extends along and around the pin post 54. The first and second electrical contacts 56, 58 are separated from one another by an insulating member 60 for electrically insulating the first and second electrical contacts 56, 58 from one another. As shown, the pin post 54 can be disposed centrally within the adapter 8. In some embodiments, as shown, the pin post 54 is substantially cylindrical in shape, such as cylindrical. Of course, the pin post 54 can have any other suitable shape. Figure 3

[0061] The adapter 8 also includes a third electrical contact 62, a fourth electrical contact 64, and a fifth electrical contact 66. Each of the third, fourth, and fifth electrical contacts 62, 64, 66 has an annular shape. As can be seen in Figure 3 As can be seen in this view, the third and fourth electrical contacts 62, 64 are separated from one another by an annular insulating member 68. As can be seen in Figure 3 As can be seen in this view, the support structure 22 defines an outermost annular wall 70. The fifth electrical contact 66 is mounted against an inner surface (not visible in this view) of the outermost annular wall 70. From Figure 3 ​It will also be apparent from

[0062] Although not visible in Figure 3 , the third and fourth electrical contacts 62, 64 provide live and neutral connections within the adaptor 8. In other words, they facilitate the supply of electrical power to the adaptor 8 and to powered components connected to the adaptor 8. When the adaptor 8 is mounted to the liquid heating vessel 4, the third and fourth electrical contacts 62, 64 can ultimately connect to powered components, such as the heating element 16.

[0063] In a similar manner, although not visible in Figure 3 , the fifth electrical contact 66 can provide a ground connection within the adaptor 8, the control device 12 and the liquid heating vessel 4 in which the control device 12 is mounted.

[0064] The control assembly 13 can take the form of a 360° cordless control assembly, whereby the adaptor 8 can be placed on the cordless base connector 10 in any angular orientation. This is achieved by the adaptor 8 having a cylindrical profile and the cordless base connector having a corresponding and complementary cylindrical profile.

[0065] Figure 4 A cross-sectional view through the control device 12, focussing on the adaptor 8 therein, is shown. The pin 54, together with the first and second electrical contacts 56, 58, along with the third, fourth and fifth electrical contacts 62, 64, 66, can be seen more clearly in this view. As can be seen in Figure 4 , the adaptor 8 extends substantially along an axis shown by the dashed line A-A. This axis extends through the centre of the adaptor 8 and thus through the centre of the pin 54.

[0066] In some embodiments, as Figure 4 shown, the annular insulating member 68 has a greater length along the axis A-A than the third and fourth electrical contacts 62, 64. As a result, this forms an annular edge 72 at the top of the annular insulating member 68 on which there are no electrical contacts. This increases the separation in the free space between the third electrical contact 62 and the fourth electrical contact 64, further minimising the likelihood of an electrical arc occurring therebetween.

[0067] Figure 5 A perspective view of the support structure 22 of the control device 12 is shown, the support structure containing the adaptor 8 formed therein. Thus, the support structure 22 is a support structure for the adaptor 8. The support structure 22 can be formed from a single piece of injection moulded plastic. The support structure 22 includes a number of contact receiving portions, as will now be described with reference to the accompanying drawings.

[0068] Figure 6A perspective view of the support structure 22 of the control device 12 is shown, focusing on the adapter 8 therein. The outermost annular wall 70 and the annular insulating member 68 can be seen more clearly in this view. The outermost annular wall 70 and the annular insulating member 68 are formed integrally with the support structure 22. As can be seen in this view, the adapter 8 includes a hole 74 that is configured to receive the pin post 54 therein during assembly of the control device 12. Thus, the hole 74 can be considered a pin post receiving portion, as it is shaped and positioned to receive the pin post 54. The support structure 22 can include another structure that receives the pin post 54 and / or the module 28 of which the pin post 54 is a part, which is located on the side opposite that shown. Figure 6 the side opposite that shown.

[0069] In Figure 6 In the embodiment shown, the annular insulating member 68 is used to form both the first and second annular receiving portions. The inner side surface 69 defines the first annular receiving portion, as it is the surface against which the third electrical contact 62 is mounted. The outer side surface 71 defines the second annular receiving portion, as it is the surface against which the fourth electrical contact 64 is mounted. The inner side surface 73 of the outermost annular wall 70 also defines a third receiving portion for receiving the fifth electrical contact 66.

[0070] Figure 7 A view of the bottom side of the support structure 22 is shown. With reference to both Figure 6 and Figure 7 The support structure 22 includes a number of mounting holes for mounting various electrical contacts thereto. Specifically, the support structure 22 includes third electrical contact mounting holes 76A, 76B that receive protruding features on the third electrical contact 62. The support structure 22 also includes fourth electrical contact mounting holes 78A, 78B for receiving protruding features on the fourth electrical contact 64. The support structure 22 also includes fifth electrical contact mounting holes 80A, 80B for receiving protruding features on the fifth electrical contact 66. The support structure 22 also includes third, fourth, and fifth electrical contact connection holes 92, 94, 96 through which a connection tab of each of the corresponding third, fourth, and fifth electrical contacts 62, 64, 66 can extend for connection to components or circuitry within the control device 12. While specific forms of mounting features are set forth above, it will be appreciated that the support structure 22 can include any suitable receiving portions capable of receiving pin posts and various electrical contacts.

[0071] Figure 8 A top view of the support structure 22 is shown, and illustrates how the third, fourth, and fifth electrical contact mounting holes 76A, 76B, 78A, 78B, 80A, 80B, along with the third, fourth, and fifth electrical contact connection holes 92, 94, 96, extend through the entire depth of the support structure 22 to the top surface 98 of the support structure 22.

[0072] Figure 9 A cross-sectional view through the support structure 22 is shown, focusing on the adapter 8 therein. As seen in this figure, the adapter 8 can include an upstanding annular wall 100 in addition to the annular insulating member 68 and the outermost annular wall 70. The upstanding annular wall 100 can extend along the axis of the adapter 8 (as shown by dashed line A-A) to a lesser length than the annular insulating member 68. The upstanding annular wall 100 can serve to assist in positioning the third electrical contact 62 within the adapter 8, and can further assist in supporting the third electrical contact 62 in place. The upstanding annular wall 100 can also serve to provide a suitable amount of electrical insulation between the base of the second electrical contact 58 and the base of the third electrical contact 62, such that the two electrical contacts can each be at a different electrical potential.

[0073] Figure 10 A view of the control device 12 is shown, with various components hidden to more clearly show the electrical connections within the control device 12. As seen in this figure, the first electrical tab 32 is in electrical contact with a first intermediate connecting member 102, which is connected to a first connecting tab 104 extending from the fourth electrical contact 64. The second electrical tab 34 is in electrical contact with a second intermediate connecting member 106, which is connected to a second connecting tab 108 extending from the third electrical contact 62. In this way, the first electrical tab 32 provides a means for connecting to the fourth electrical contact 64, while the second electrical tab 34 provides a means for connecting to the third electrical contact 62. The first and second electrical tabs 32, 34 can provide live and neutral connections to electrical components within the liquid heating vessel 4, such as the heating element 16.

[0074] As previously discussed, in some embodiments the pin 54 can be part of the module 28 that can be inserted into the support structure 22, in order to quickly and easily form the adapter 8. Figure 11 A module 28 is shown that can be inserted into the control device 12. The module 28 includes a pin 54 that includes first and second electrical contacts 56, 58 separated by an insulating member 60. The module 28 includes a mounting body 110 to which the various components of the module 28 are mounted. The module 28 also includes an electrical component in the form of a temperature sensor 30. The temperature sensor 30 can include a negative temperature coefficient (NTC) thermistor. The following figures show cross-sectional and partial views of the module 28 to illustrate its various components.

[0075] Figure 12A cross-sectional view through module 28 is shown. As can be seen in this figure, module 28 can include a spring member 112, for example in the form of a coil spring 112, which can be arranged to elastically bias temperature sensor 30 in an upward direction. This elastic bias on temperature sensor 30 can serve to keep temperature sensor 30 in close contact with the component whose temperature it is monitoring when control device 12 is mounted to liquid heating vessel 4. First and second electrical wires 126, 128 extend from temperature sensor 30 and are connected to first and second electrical contacts 56, 58, respectively.

[0076] Figure 13 A mounting body 110 of module 28 is shown in an isolated state. As can be seen in this figure, insulating member 60 is integrally formed with mounting body 110. Mounting body 110 includes a pin post portion 114 which serves to provide insulating member 60. Pin post portion 114 includes a hollow core (not visible in this figure) through which first electrical contact 56 extends. Pin post portion 114 includes an opening at an end thereof such that first electrical contact 56 protrudes from a tip 116 of pin post portion 114 when inserted therein. Pin post portion 114 also includes a contact receiving portion 118 which includes a circumferential portion 120 and an axially extending portion 122. Circumferential portion 120 and axially extending portion 122 receive corresponding portions of second electrical contact 58. Although not visible in this figure, a base 124 of mounting body 110 includes corresponding openings through which first and second electrical contacts 56, 58 can extend to facilitate electrical connections within module 28. Mounting body 110 also includes a mounting feature 130 which can be used to secure module 28 in place on control device 12. Mounting feature 130 can engage with a correspondingly shaped protrusion on support structure 22 which serves to hold module 28 in place on control device 12.

[0077] Figure 14 A perspective view of second electrical contact 58 is shown in an isolated state. As can be seen in this figure, second electrical contact 58 includes a circumferentially extending portion 138 which is shaped to extend around circumferential portion 120 on mounting body 110. Second electrical contact 58 also includes an axially extending portion 140 which is shaped to seat on axially receiving portion 122 on mounting body 110. Second electrical contact 58 also includes a contact tab 142 to which second electrical wire 128 (as shown) can be connected. Figure 12

[0078] Figure 15 ​A perspective view of the first electrical contact 56 is shown in isolation. The first electrical contact 56 comprises an elongate portion 144 shaped and dimensioned to extend through the hollow core of the contact receiving portion 118 such that a tip 146 of the first electrical contact 56 protrudes from the contact receiving portion 118. The tip 146 allows for an electrical connection to be made with the first electrical contact 56.

[0079] Figure 16 A perspective view of the connector 10 of the control assembly 13 is shown. In this view the corresponding third, fourth and fifth electrical contacts 46, 48, 50 can be seen. Figure 17 A cross-sectional view through the connector 10 is shown. As can be seen in this view, within the hollow core 152 of the central boss 38, the corresponding first electrical contact 148 and the corresponding second electrical contact 150 are arranged. As shown, the corresponding first electrical contact 148 is oriented such that the tip of the contact pin 54, and thus the end of the first electrical contact, is contacted. In contrast, the corresponding second electrical contact 150 is oriented such that the second electrical contact 58 is contacted.

[0080] Referring to the above figures, when the control device 12, and in particular its adaptor 8, is mated with the connector 10, an electrical connection will be formed between them. In particular, the first electrical contact 56 will contact the corresponding first electrical contact 148 and the second electrical contact 58 will contact the corresponding second electrical contact 150. These contacts 56, 58, 148, 150 can be used to provide data transmission between the adaptor 8 and the connector 10. In this way, when contacted, data can be transmitted from the temperature sensor 30 to the connector 10, for example to a controller arranged in the cordless power base 6.

[0081] When mated, the third electrical contact 62 will contact the corresponding third electrical contact 46 and the fourth electrical contact 64 will contact the corresponding fourth electrical contact 48. As such a contact provides a live and neutral connection, this can facilitate power transmission between the adaptor 8 and the connector 10.

[0082] Similarly, when mated, the fifth electrical contact 66 will contact the corresponding fifth electrical contact 50. These contacts can provide a ground connection between the adaptor 8 and the connector 10.

[0083] The above described embodiment is not the only form that a control device can take. Figure 18 A perspective view of a control device 1012 according to another embodiment of the present application is shown. The control device 1012 is substantially the same as the control device 12 described above, with some minor differences described below. Importantly, however, the control device 1012 comprises an adaptor 1008 which corresponds substantially to the adaptor 8 described above.

[0084] Unlike in the above described embodiment, in which the temperature sensor 30 is provided as part of the module 28, in the control device 1012 the temperature sensor 30 is provided as part of the adaptor 1008.Figure 18 In the illustrated embodiment, the temperature sensor 1030 is mounted on a bracket 1154, which extends away from the support structure 1022 of the control device 1012. The bracket 1154 can be mounted onto a metal plate 1024. In this embodiment, the first and second cables 1126, 1128 are longer than those in the embodiments discussed above. The ends of the cables 1126, 1128 include spade-shaped connectors 1156, 1158, one of which can be... Figure 18 See in (another one can be seen from) Figure 21 (See shown in the image). Each of the spade-shaped connectors 1156 and 1158 can be properly connected to the first and second electrical contacts of the adapter 1008. Figure 18 (Not shown in the image).

[0085] Figure 19 Another embodiment of the control device 2012 is shown. Except for the differences described below, the control device 2012 is substantially the same as the control device 12 described above. Unlike the first embodiment discussed above, the temperature sensor 2030 in this further embodiment is also not configured as part of the module. Instead, the temperature sensor 2030 is simply mounted to the metal plate 2024 on top of the control device 2012. The first and second cables 2126, 2128 also extend from the temperature sensor 2030 and terminate with spade-shaped connectors 2156, 2158 that are appropriately connected to the first and second electrical contacts (not visible in this figure).

[0086] Figure 20 Showing Figure 18 The diagram shows a view of the control device 1012, with the metal plate 1024 and bracket 1154 concealed to expose the underlying components. As can be seen in the figure, first and second shovel-shaped connectors 1156, 1158 are connected to first and second intermediate connectors 1160, 1162, which are connected to the contact tab 1142 of the second electrical contact (not visible in this figure) and the contact tab 1147 of the first electrical contact (not visible in this figure). Therefore, the temperature sensor is connected to both the first and second electrical contacts.

[0087] Figure 21A view of the bottom side of the control device 1012 is shown, with only a limited number of electrical components shown to illustrate the electrical connections between the temperature sensor 1030. As can be seen in this figure, the contact tab 1147 of the first electrical contact 1056 is in contact with the second intermediate connector 1162, and the contact tab 1142 of the second electrical contact 1058 is in contact with the first intermediate connector 1160. Spade connectors 1156, 1158 are connected to the first and second intermediate connectors 1160, 1162, thereby providing an electrical connection to the temperature sensor 1030. These figures thus demonstrate how the temperature sensor 1030 is connected to the first and second electrical contacts.

[0088] In the above-described embodiments, the control assembly takes the form of a 5-pole control assembly. However, in some embodiments of the present application, the control assembly can include fewer contacts. Thus, Figure 22 A perspective view of another control assembly 3013 according to another embodiment of the present application is shown. Similar to the previous embodiments, the control assembly 3013 includes a control device 3012 that includes an adapter 3008. The control assembly 3013 also includes a cordless base connector 3010. However, unlike the above-discussed embodiments in which the adapter and the connector each include five electrical contacts, the adapter 3008 and the cordless base connector 3010 each include three electrical contacts, thereby making this embodiment a 3-pole control assembly 3013. Although this embodiment is shown as including a control device 3012, it should be understood that the adapter 3008 need not be part of such a control device 3012, but can be provided in a separate state.

[0089] Importantly, in Figure 22 In the illustrated embodiment, the support structure 3022 is identical to the support structure 22 of the above-described embodiments. Thus, a single support structure is used to form both 5-pole and 3-pole control assemblies. This can reduce the number of different parts that must be manufactured in order to manufacture different control assemblies.

[0090] Figure 23 A perspective view of the bottom side of the control device 3012 is shown. In this embodiment, the adapter 3008 includes a different pin post 3054 that includes only the first electrical contact 3056, rather than both the first and second electrical contacts. The adapter 3008 also includes a second electrical contact 3062 (which is identical to the third electrical contact 62 of the above-described embodiments) and a third electrical contact 3064 (which is identical to the fourth electrical contact of the above-described embodiments). In this embodiment, there is no fifth electrical contact that is inserted into the adapter 3008.

[0091] Figure 24A view of the control device 3012 is shown with several of its components hidden in order to more clearly show the electrical connections to the second and third electrical contacts 3062, 3064. As can be seen in this figure, the first power connection tab 3160 can be connected to the first connection tab 3104 extending from the second electrical contact 3062, and the second power connection tab 3162 can be connected to the second connection tab 3108 extending from the third electrical contact 3064. The first and second power connection tabs 3160, 3162 can be connected to any components within the liquid heating vessel that require power.

[0092] Figure 25 A perspective view of the cordless base connector 3010 is shown. As can be seen in this figure, the cordless base connector 3010 includes a corresponding first electrical contact 3148, a corresponding second electrical contact 3046, and a corresponding third electrical contact 3048. Although not shown in this embodiment, the cordless base connector 3010 can include a connector support structure that is identical to the connector support structure of the 5-pole cordless base connector 10 described above.

[0093] In any of the embodiments described above, although the adapter is shown as part of the control device, it will be appreciated that the control device can be omitted and the adapter can be provided in a separate state, or alternatively form part of a different component.

[0094] In the embodiment of the 5-pole adapter 8 described above, the first and second electrical contacts 56, 58 are axially displaced along the pin post 54. However, this is not essential and, instead, the contacts can be circumferentially displaced. Figure 26 A perspective view of a pin post 4054 according to another embodiment of the present application is shown. As shown in this figure, the pin post 4054 includes first and second electrical contacts 4056, 4058. However, unlike the previous embodiments in which the electrical contacts are spaced along the axis A-A, in this embodiment, the first and second electrical contacts are spaced around the circumference of the pin post 4054. Even with this arrangement, electrical connections can be achieved that are independent of the angular orientation of the adapter and the corresponding connector by appropriately positioning the corresponding contacts within the cordless base connector.

[0095] As set out above, the 3-pole and 5-pole control assemblies each include an adapter having a common support structure. Figure 27 A flow chart of a method for forming an adapter for a control assembly according to one embodiment of the present application is shown, which illustrates how a common support structure can be used to form different adapters.

[0096] The method comprises forming a support structure in step S1. The support structure formed in step S1 can be in the form of the support structure 22 described above. The support structure can be formed by injection moulding. In step S2, a determination is made as to whether a pin post is required. The determination can be based on an assessment of how many electrical contacts are required within the adapter.

[0097] If a pin post is required, the method proceeds to step S3 in which either a first pin post comprising a first electrical contact is selected, or a second pin post comprising a first electrical contact and a second electrical contact is selected. The first pin post can be selected when it is desired to produce a 3-pole adapter, and the second pin post can be selected when it is desired to produce a 5-pole adapter. The method then proceeds to step S4 in which the selected pin post, i.e. the first or second pin post, is inserted into the support structure. The method then proceeds to step S5 in which a third electrical contact having an annular form is inserted into the first annular contact receiving portion. Subsequently, the method proceeds to step S6 in which a fourth electrical contact is inserted into the second annular contact receiving portion. In the case that a 5-pole adapter is required and the second pin post is selected and inserted in steps S3 and S4, the method can further comprise step S7 in which a fifth electrical contact is inserted into the third receiving portion.

[0098] When it is determined in step S2 that a pin post is not required, for example because a ground connection is not required, the method can instead proceed to steps S5 and S6, whereby the third and fourth electrical contacts are inserted, and steps S3 and S4 can be omitted. This can result in the formation of a 2-pole adapter.

[0099] Although the method has been explained above in the order in which it is performed, it will be appreciated that the steps of the method can be performed in any suitable order. For example, steps S5, S6 and S7 in which the third, fourth and optionally fifth electrical contacts are inserted can be performed before steps S2, S3 and S4 in which it is determined whether a pin post is required, the pin post is selected and the pin post is inserted. It will also be appreciated that in some embodiments, in which it is predetermined that the adapter must comprise a pin post, the step of determining whether a pin post is required can be omitted and the method can proceed directly to steps S3 and S4.

[0100] The method described above can equally be applied to the formation of a cordless base connector. The method can comprise forming a connector support structure, and subsequently inserting an appropriate number of corresponding first, second, third, fourth and fifth electrical contacts into the connector support structure. The cordless base connector can thus comprise a corresponding number of contacts to the adapter with which it is to be paired.

[0101] While the application has been described in detail only in connection with a limited number of embodiments, it should be readily understood that the application is not limited to such disclosed embodiments. Rather, the application can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not heretofore described but which are commensurate with the scope of the application. Additionally, while the application has been described as having exemplary designs, the present application can be further modified within the spirit and scope of the disclosure. Accordingly, the application should not be limited to the preceding description but is only limited by the scope of the appended claims.

Claims

1. A control assembly for a cordless liquid heating appliance comprising a liquid heating vessel and a cordless power base, the control assembly comprising: a cordless base connector for mounting to the cordless power base; and an adapter for mounting to the liquid heating vessel, the adapter configured to mate with the cordless base connector when the liquid heating vessel is seated on the cordless power base, wherein the adapter comprises: a pin post comprising a first electrical contact and a second electrical contact, the first and second electrical contacts arranged to connect with corresponding first and second electrical contacts in the cordless base connector; a third electrical contact having an annular form extending around the pin post and radially displaced from the pin post, and arranged to connect with a corresponding third electrical contact in the cordless base connector; and a fourth electrical contact having an annular form extending around the third electrical contact and radially displaced from the third electrical contact, and arranged to connect with a corresponding fourth electrical contact in the cordless base connector; wherein the third and fourth electrical contacts in the adapter and the corresponding third and fourth electrical contacts in the cordless base connector are configured to provide live and neutral connections to the liquid heating vessel. the adapter further comprises a fifth electrical contact radially displaced from the pin post, and arranged to connect with a corresponding fifth electrical contact in the cordless base connector, and wherein the fifth electrical contact is configured to provide a ground connection to the liquid heating vessel.

2. The control assembly of claim 1, wherein, the fifth electrical contact is radially outwardly displaced from the fourth electrical contact.

3. The control assembly of claim 2, wherein, the fifth electrical contact has an annular form.

4. The control assembly of claim 2 or 3, wherein, the first and second electrical contacts in the adapter and the corresponding first and second electrical contacts in the cordless power base together provide a signal connection for transmitting data between the adapter and cordless base connector.

5. The control assembly of any of the preceding claims, wherein, the adapter forms part of a control device for mounting to the liquid heating vessel.

6. The control assembly of any preceding claim, wherein, the control device comprises an electronic component, the first and second electrical contacts of the pin post being electrically connected to the electronic component.

7. The control assembly of claim 6, wherein, the pin post and electronic component form a module for insertion into the adapter.

8. The control assembly of claim 7, wherein, the electronic component comprises a temperature sensor.

9. The control assembly of claim 7 or 8, wherein, the third and fourth electrical contacts are separated by an annular insulating member, wherein the third electrical contact is in contact with an inwardly facing surface of the annular insulating member, and wherein the fourth electrical contact is in contact with an outwardly facing surface of the annular insulating member.

10. The control assembly according to any of the preceding claims, wherein, the pin post comprises an insulating member arranged between the first and second electrical contacts.

11. The control assembly according to any of the preceding claims, wherein, the first and second electrical contacts are separated from each other along an axis of the pin post.

12. The control assembly according to any of the preceding claims, wherein, the first and second electrical contacts are separated from each other around an axis of the pin post.

13. The control assembly of any of the preceding claims, wherein, the pin post has a substantially cylindrical shape.

14. The control assembly according to any of the preceding claims, wherein, the control assembly is a 360° cordless control assembly.

15. The control assembly according to any of the preceding claims, wherein, the pin post is disposed centrally of the adapter.

16. The control assembly according to any of the preceding claims, wherein, 17. A cordless liquid heating appliance comprising: ​ a cordless power base for connection to a mains power supply; a liquid heating vessel configured to be seated on the cordless power base; and a control assembly according to any of the preceding claims, wherein the adapter is mounted to the liquid heating vessel, and wherein the cordless base connector is mounted to the cordless power base.

18. The liquid heating appliance of claim 17, wherein, The liquid heating vessel comprises a chamber for receiving a volume of liquid to be heated, and a heating element for heating the liquid within the vessel, and wherein the third electrical contact and the fourth electrical contact are electrically connected to the heating element.

19. A support structure for forming at least part of an adapter configured to provide electrical connection with a corresponding cordless base connector, the support structure comprising: a pin post receiving portion capable of receiving a plurality of different types of pin posts, the pin posts comprising at least a first pin post with a first electrical contact and a second pin post with a first electrical contact and a second electrical contact; a first annular contact receiving portion capable of receiving a third electrical contact having an annular form; a second annular contact receiving portion capable of receiving a fourth electrical contact having an annular form; and a third receiving portion capable of receiving a fifth electrical contact.

20. The support structure of claim 19, wherein, The first annular contact receiving portion, the second annular contact receiving portion and the third receiving portion are radially displaced from each other relative to the pin post receiving portion.

21. The support structure of claim 19 or 20, wherein, The support structure comprises only the pin post receiving portion, the first annular receiving portion, the second annular receiving portion and the third receiving portion for receiving electrical contacts.

22. The support structure of any one of claims 19-21, wherein, The support structure is formed from a plastic body.

23. A method of forming at least one adapter of a control assembly, the adapter being configured for mounting to a liquid heating vessel, the method comprising the steps of: forming a support structure according to any of claims 19 to 22; determining whether a pin post is required and when a pin post is required: selecting one of a first pin post with a first electrical contact and a second pin post with a first electrical contact and a second electrical contact; and inserting the selected pin post into the pin post receiving portion; inserting a third electrical contact having an annular form into the first annular contact receiving portion; and inserting a fourth electrical contact having an annular form into the second annular contact receiving portion.

24. The method of claim 23, further comprising inserting a fifth electrical contact into the third receiving portion. The second pin post with the first electrical contact and the second electrical contact is part of a module, the module comprising the second pin post and integrated electronic components electrically connected to the first electrical contact and the second electrical contact of the second pin post.

25. The method of claim 23 or 24, wherein, ​

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