types of iron box

TYPES OF IRON BOX

1. Automatic
2. non automatic
3. steam iron box

AUTOMATIC-

• Temperature is regulated

• consists of a thermostatic device
• parts :Pilot lamp,built in automatic heat adjustment

these r the main parts to b remembered others parts can b easily remembered

• handle --- common for all iron  box

• metal plate ----by which we iron

•  cord to b connected to the plug

•  cover---cover all its parts

thermostat - nothing simple

1.  it is nothing but two metals connected together when currents passes through it ,it expands and so sole plate gets heated when cooled it contracts
2. in this two metals one has high rate of expansion other has low rate of expansion
3. one metal will be placed up and ther will b placed down when heated high expanding metal will expand faster and will curl or bend downwards from the low expanding metal hence contacts gets lost and it cools after cooling it contracts and gets in contact with it

NON AUTOMATIC TYPE

• temperature is not regulated
• doesnt consists of a thermostatic device
• need manual temperature adjustment
• that is switching on and off the device

these r the main parts to b remembered heating element,heel plate, sole plate, pressure plate
heating elements

• this can b of 2 types
• nichrome resistance with mica
• round resistance with ceramic coil

pressure plate
as from its name it gives pressure to the sole plate as it is fixed to the heating element or in simple words kept as a weight as we keep a paper weight on a paper such that it is fixed in a plate
heel plate
it is very simple it used for making iron stand when we finish ironing ne side of the cloth we keep iron in the table supported by its handle
sole plate is the very common part in iron box it is the plate by which we iron clothes
STEAM IRON
                               

In the earlier days steam irons were used, but now the electric iron is preferred over the steam ones. Steam irons have some maintenance issues due to clogging. Steam irons usually have vents through which the water passes. As the steam iron gets used, slowly the minerals from the water accumulate at the vents and blocks the water from passing through. Thus the efficiency of the steam iron is compromised. So the steam iron has to be cleaned and maintained regularly to ensure its proper working. If you live in an area where hard water is used, then clogging is a major problem.

The Manufacturing Process

First, each sub-assembly of the iron is produced, most often on separate, automated production lines. Then the iron is assembled.

Sole plate

• 1 The sole plate is cast of molten aluminum. Part of the mold creates the holes that are essential in a steam iron. Heated metal is inserted into a mold under pressure, cooled, and released.
• 2 The cooled sole plate is treated in one of three ways. It is polished, coated with a non-stick PTFE material, or covered with another metal. Such metals include stainless steel.
• To complete one or more of these processes, the sole plates are put on a large automated carousel, which rotates through each step.
• 3 To polish the plate, an automated belt sander uses bands of abrasive to polish and buff the plate. The finish required determines which grade of abrasive is used.
• 4 An automated spray-painting machine applies non-stick coating. After application, the sole plate is baked in an automated industrial process.
• 5 To coat with another metal, the external metal cover is created by an automated stamp press. The resulting cover is either pressed or riveted onto the sole plate, through a smaller machine press.

Thermostat

• 6 In an injection mold, a small metal post is cast.
• 7 A spring is mounted onto the metal post. This spring is a bimetallic switch made of two different metals with divergent linear thermal coefficients bonded together. The spring actually controls the iron's temperature.
• 8 Power contacts are attached to the end of the spring, which let the electricity through so the iron can be heated. This whole process is generally automated.

Water tank

• 9 In a two-part injection mold, heated plastic is inserted to make upper and lower sections of the tank. Several openings on the tank are created as part of the mold.
• 10 The mold is put under pressure, cooled, and released as a one-part tank.
• 11 Other parts for the tank (pump, internal chamber, piston, buttons, and other parts) are created by similar injection molding processes.
• 12 On an automated assembly line, the parts are put together, with each of the other parts put onto the water tank.

Housing

• 13 In an injection mold, heated plastic is inserted into a mold under pressure, cooled, and released.

Handle

• 14 In an injection mold, heated plastic is inserted into a mold under pressure, cooled, and released.

Assembly

When all the parts are manufactured, the iron is assembled on an automated assembly line.

• 15 The sole plate is the first part on the assembly line. The thermostat is either screwed onto the plate, or welded to the plate by a robot.
• 16 To the sole plate-thermostat subassembly, the water tank is put in place. It is secured on an automated line with screws or other industrial fasteners.
• 17 The handle and body are attached over the sole plate, thermostat and water tank, and fixed by screws. Sometimes this process is automated, but it also can be done manually.
• 18 The electrical cord is the last piece to be added. Sometimes this process is automated, but it also can be done manually.
• 19 After an automated testing process, the irons are inspected by hand.
• 20 Completed irons are packed into indidual boxes with instructions and other documents by hand. (For some companies, this is an automated process.)
• 21 The individual boxes are placed in shipping cartons or master packs for distribution to warehouses.

Quality Control

Before the manufacturing process begins, all the raw materials are sample checked for consistency. As each subassembly of the iron is manufactured, the pieces are checked for correct functionality.

During the assembly process, an iron is removed from the production line and taken apart by an independent department to look for errors. Any mistakes result in the whole batch of irons being checked and corrected if necessary. After the product is assembled, a worker also checks the iron for electrical functionality and water integrity.

Byproducts/Waste

Any excess metal or plastic from the molding process is reused in the process, if possible. Anything that is unable to be used is recycled.

The Future

The most obvious improvements on the iron probably will be to the sole plate. Better coatings will probably be invented that are more resistant to damage from zippers or other protrusions on garments and reduce drag over fabric. These improvements might be in the form of better alloys or better nonstick coatings. Internal mechanisms that better control heat and steam also will continue to evolve.