Deconstruction of an Iron

From the archives of All things Ironing - How is an Iron Constructed.

 

The information in this article is drawn from an Iron manufacturer's Iron Construction manual and various websites. Links to images and related websites are located at the bottom of this article. 

 

Raw Materials

Irons are made primarily of plastic and metal. The materials often comes to the factory in the form of plastic resins, aluminum ingots, and steel sheets.

The metal is used to make the sole plate, thermostat and other internal mechanisms. Plastics are used to make the exterior and handle, as well as the water tank. Certain components, like the spring for the thermostat, cord, plug, and related connections are usually outsourced by iron companies.

Iron

The Manufacturing Process

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 from molten aluminum in a mold that already includes the steam holes.

2 The sole plate is then polished, coated with a variety of non-stick materials including teflon.

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.

Examples of soleplate types

soleplate - explained

soleplate - diagram

soleplate - steam holes

soleplate - stainless steel

soleplate - panasonic 360

soleplate - sunbeam Verve



soleplate - rowenta

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.

iron thermostat

iron thermostat diagram

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.

research links & image sources :
freepatentsonline
panasonic 360
advantech
artofmanliness 
alibaba 
brighthubengineering

Bon Voyage Sue

About Osca - Sue is off on a Pacific Cruise and a well deserved break.

Those in the know, know that Sue has been with Osca for over a decade, contributing her unique talents, boundless energy and an amazing dedication to Osca and the service we provide our clients.

Right now, Sue is somewhere in the Pacific, hopefully lounging on a deckchair, sipping a cool drink enjoying the sunshine and the trappings of a leisurely cruise.

"Enjoy your time Sue, you deserve it."

Phyllis Diller (1917- 2012)

From the archives of All things Ironing - Phyllis Diller (July 17, 1917 – August 20, 2012)

Sadly, Phyllis Diller died today, aged 95.

We remember Phyllis for her zany sense of humor, being the only quoted comedian to venture into the world of ironing.

Phyllis Diller (1917-2012)

"The only time I ever enjoyed ironing was the day I accidentally got gin in the steam iron."

Phyllis Diller

"I buried a lot of my ironing in the back yard."

Phyllis Diller

"I'm eighteen years behind in my ironing."

Phyllis Diller

Phyllis Diller was an American actress and stand up comedian, although she would probably prefer comedienne.

 

Phyllis created a stage character of an eccentric, wild-haired, zany housewife who made self-deprecating jokes about her age and appearance, her terrible cooking, and a husband named "Fang". We will miss her.

"Thank you for the best times Pyllis. Rest In Peace."

Henry Yuzuru Sugimoto (1900-1990)

From the archives of All things Ironing - Irons in oils.

Henry Yuzuru Sugimoto (1900-1990)

Henry Sugimoto - Susie ironing in room at the interment camp

Henry Yuzuru Sugimoto, an Japanece American artist, teacher and a survivor of Japanese American Internment, born in Wakayama, Japan in 1900 a son of a displaced samurai.

In 1919, he immigrated to the United States and changed his name to Henry. He graduated high school in 1924 and went on to study at California College of Arts and Crafts and the California School of Fine Arts (now the San Francisco Art Institute).

In 1928, he went to France to study at the Académie Colarossi in Paris.


In 1932, Sugimoto returned to California where he enbarked on a one-man show at the California Palace of the Legion of Honor in San Francisco. The show became the foundation of his professional career.

Sugimoto was living in the United States when the United States declared war on Japan in the Second World War. He was interned with Japanese-Americans in Jerome War Relocation Center from October 1942 through June 1944 and at Rohwer War Relocation Center until August 1945.

David McCosh (1903-1981)

From the archives of All things Ironing - Irons in oils.

David McCosh (1903-1981)

David McCosh - A woman ironing (1931)

David McCosh, an American painter and teacher, was born in Cedar Rapids, Iowa, in 1903.

In 1922, he first studied art at Coe College and a year later embarked on six years of study at the Art Institute of Chicago, from which he graduated in 1926. In 1927, McCosh won a prestigious John Quincy Adams Fellowship, enabling him to travel and paint in Europe up till 1928.

In 1930, while painting in Oyster Bay, Long Island, McCosh met Anne Kutka, a gifted painter her self. The two were married in New Mexico in July 1934.

In 1932, McCosh began teaching at the Art Institute and at the Stone City Art colony in Iowa and two years later accepted an appointment at the University of Oregon, where he taught painting, drawing, and lithography until his retirement in 1970. McCosh died in Eugene in 1981.

"Learning to paint is learning to see, not to recognise familiar things."

Although McCosh put a lot of energy and thought into teaching, painting was the focus of his life. Despite experimenting with many styles his paintings were based on careful observation. “Learning to paint,” McCosh said, “is learning to see, not to recognize only familiar things.”

Beautiful Victoria

When we are not ironing - Daytrip to Country Victoria.

Every now and then, when the daily grind gets to us, a quick remedy is a day trip to the Victorian countryside.  Kinglake, so devastated during Black Saturday three years ago is just an hour or so drive from the City.  Come through St. Andrews and you might catch a weekend market.  The road to Kinglake here is winding and narrow, but offers magnificent views of the surrounding countryside. 

Kinglake sign

This area was burned to the ground three years ago and the scars are still visible, but between the black stumps, new growth of lush green has erupted as the bush is recovering.

Make sure to stop off at the Kinglake township and visit the local stores. The locals, traders and shop keepers can do with the extra business and appreciate that we remember what they've been through when the fires ripped their lives and community apart.

Kinglake pub

You can't miss the Kinglake pub. It is one of the great "Country Pubs" in the region. The food is of excellent quality and value for money with hearty country style meals. Most of the herbs and veggies used are grown in their own veggie garden. They also offer coffee and cakes all day every day and delicious cooked breakfasts on the weekend.

By now, we can not resist and point the steering wheel down a side road that winds its way to Yea, and then its on to Alexandra and Eildon before the waether turns.



The Cathedral peeking over the hill near Taggerty

Streaks of sunlight filter through an eucalypt plantation

Brewing storm on the horizon

A solitary gum tree lit up briefly before the sun disappeared behind the clouds for the day

Returning through Healsvile, we drive by French's Laundry which burned down on July the 10th this year.

90 years in business and employing 30 people, it was a bit of a blow to Healsville.  Remarkably though, the community has rallied behind devastated owner David Nguyen and his staff, with the Healesville Football Club letting the business use its Don Rd rooms as a headquarters.



Not much remains of French's laundry after it was consumed by fire

French's are now operating from a temporary factory in Hunter Rd, until the owners find a bigger factory to move into.


The folks at French's Laundry have been looking after our customer's linen and large laundry for 20 years, so it is good news to hear they are battling on, saving the 30 jobs and rebuilding. There is that remarkable country spirit again.

Miles of Ironing

From the archives of All things Ironing - Miles of Ironing.

I have not been able to verify the original source of this story, having found various web articles claiming authorship but all having identical text. In essence, they were quoting a survey from 2008 which came up with some startling results which I will try to relate to you for the purpose of your entertainment.

photo modified by Osca

According to the survey -

Men iron a whopping 73 miles in their entire lifetime

while

Women iron an impressive 215 miles.

215 miles is roughly equivalent to 8 marathons.
That is a bout 2 whole days of ironing each year.

The poll, of 3500 adults found that 45% of men deliberately do the ironing badly

so their loving wife will take over.

25% of men admitted they still get their mums to do their ironing.

The poll also showed that the average person will iron 20 bits of clothing every week, including four pairs of trousers, 15 tops or shirts and a piece of underwear.

According to the survey, 3pm on a Sunday is the favourite time to do the ironing.

A quarter of the people who took part in the survey described ironing as 'theraputic'.

1 in 5 admitted they used ironing as an excuse to get away from husbands/wives, children etc.

Moreover, half admitted they had ruined clothes due to their lack of skill in ironing.

We say - All the more reason to call Osca and let us take the ironing off your hands.

Osca Ironing Franchise Logo successfuly trade marked

About Osca - Osca logo.

While Osca will continue to trade with the Logo we have all come to know and love, it was suggested as a good idea to trademark a separate Osca Ironing logo for the Osca Ironing Franchises to make sure we had the right trade protection for our future franchisees.

The Osca logo artwork was originally designed by Marjory Gardner, a leading Australian children's book illustrator way back in the 1980's with a subsequent re-visit in 2009.

Marjory Gardner

Current Osca logo

Osca logo evolution

New Osca Ironing Franchise logo

One more step closer to getting the Osca Ironing franchises off and running, we have successfuly applied to trade mark an Osca Ironing logo.

DIY Ironing Chair

From the archives of All things Ironing - Ironing chair.

Hard up for space and nowhere to do your ironing?

Here is a Do It Yourself solution - an inexpensive and practical high-back valet chair that unfolds to become a compact ironing board!

This humble pine ironing chair asks little in the way of space while providing two coat pegs, shoe storage and underside accommodations for cuff links and tie clips. And when the heat's on, the hinged bottom and back can be locked horizontally to take care of any "pressing engagements."

The denim upholstery fabric, backed with cotton underlay is tough enough to serve well in either capacity.

story source

image source

Iron Lady Ironing

From the archives of All things Ironing - Margaret Thatcher ironing.

Margaret Thatcher, the 'Iron Lady' offered to pay for an ironing board for No 10 after becoming PM, having insisted on using her own household items.

In documents from 1979, kept secret until 2009, the Iron Lady said she could provide her “own crockery” and “an excellent ironing board”.

story source
image source

Kate and Charles Ironing

From the archives of All things Ironing -  Kate and Charles ironing.

For Kate it was a day out with her father-in-law. For Charles, it was a chance to learn new skills.

"Do I keep ironing that? I am going to be here all afternoon!" Charles joked.

story source
image source

Tony Abbott Ironing

From the archives of All things Ironing - Tony Abbott ironing

While the political debate over this news story descended into a gender based row, we note the perfect single crease on Tony Abbotts shirt sleeve.

Source - ABC News February 09, 2010

Australian Federal Opposition Leader Tony Abbott taking a turn at ironing a shirt during a visit to a Queanbeyan Dry Cleaning business.

story source
image source

Care Labels explained

Osca Newsletter 23.7.2012 - Useful information.

Garment Care labels can sometimes be confusing.

Before you take that next perfect garment home, always check the care label. We all want our new addition to the wardrobe to continue looking as great as the day we bought it for as long as possible, but inevitably, there comes a day when it needs to be washed or dry cleaned and inevitably ironed.

At Osca, we always try to check the labels before we iron your garments so please don't remove the label even if it is a little scratchy on the skin. It is the best way to make sure your garments are ironed to perfection.

Advances in chemistry and nano-technology mean new fabrics are being manufactured all the time. Just because a fabric looks like cotton and feels like cotton to the touch, it may not be.  A wrong temperature washing machine setting or a wrong setting on the iron can ruin a garment in seconds so to ensure your garment is taken care of correctly, always follow the manufacturer's instructions.

Here is a list of the most common garment care labels to help you make the right choice, whether, buying, washing, dry-cleaning or ironing your garments.

image source

Rid Jid Ironing board

From the archives of All things Ironing - Humor.

It is a better world we live in when this advertising for a Rid Jid Ironing table is so ridiculous that it is almost funny.

The text in the advertisement reads -

You are a Dear, Thoughtful Husband !

"You're always seeking some way to make work lighter and easier. And this Rid-Jid ironing table will help wonderfully. I've wonted one for months. It not only makes my Christmas happy but my ironing will never be a task anymore!"

"And it's so strong, and so convenient. It can't creep or crawl, and never has to be lifted to put on and take off circular garments."

See your dealer early and reserve one for wife, mother, daughter or sister.

Advice to men from Osca - Do Not Try This At Home !

What impact will the Carbon Tax have on our prices ?

Osca Newsletter 23.7.2012 - There will be no increase to our prices as a result of the Carbon Tax.

Carbon Tax Word Cloud

As an Osca customer, you will know that we have identified reducing our carbon footprint as a priority many years ago and have installed energy saving devices, introduced new procedures and even changed the equipment we use to iron your garments with. Instead focusing on achieving quality of ironing with additional training.

When the introduction of the carbon tax became inevitable, we were obviously concerned about the impact it would have on our prices. So we did the calculations.

Assuming that our electricity bill may rise by approximately 10%, we took the increase, divided it by the number of weeks, the number of working days per week and the number of customers per day. Even we were surprised at the result. The total impact of the carbon tax on our power bill would be about 13 cents per customer per booking.  The amount is quite small when we divide that figure by the number of items per customer.

Of course it will probably take a few months to really see, as our suppliers make their determinations, but at this stage we see no need to increase our prices as a result of the introduction of the Carbon Tax.

image source

... on the chemistry of Ironing

From the archives of All things Ironing - Ironing chemistry.

When a fabric is heated, the molecules of the cotton fibres are more easily reoriented. In the case of cotton fibres, which are derivatives of cellulose, the hydroxyl groups that crosslink the cellulose polymer chains are reformed at high temperatures, and become "locked in place" upon cooling of the fabric.

Cellulose is the major constituent of textiles made from cotton, linen, and other plant fibers.

Ironing works by loosening the bonds between the long-chain polymer molecules in the fibers of the material. While the molecules are hot and pliable, the fibers are straightened by the weight of the iron, and they hold their new shape as they cool. Some fabrics, such as cotton, require the addition of water to loosen the intermolecular bonds.

Many modern fabrics (developed in or after the mid-twentieth century) are advertised as needing little or no ironing because chemical agents such as dimethylol ethylene urea are added as crosslinking agents to keep textile fibres stable.

... on the history of Ironing.

From the archives of All things Ironing - History of ironing.

It isn't exactly clear when people started trying to press cloth, but it is said that the Chinese were using hot metal for ironing before anyone else.

Pans filled with hot coals were pressed over stretched cloth as illustrated in this image. Acording to some records, this method was already well-established in China well over a thousand years ago.

image source

Signs of our times

From the archives of All thing Ironing - It's a Sign.

Jerusalem, Israel

Electricity before Steam

From the archives of All things Ironing - H.W. Seely.

Before the Steam Iron came the Electric Iron.

Born in Richville, Kentucky, on July 2nd, 1854 Henry W. Seely invented and patented the first electric pressing iron on the 6th of June in the year 1882. The invention was named as the “electric flatiron.”

H.W.Seely

Although it is the only invention Seely patented, he witnessed many of Thomas Edison's inventions, including the light bulb.

Unlike current models, the first irons manufactured, used a carbon arc to create the heat needed by passing a current across carbon arc electrodes.

 

  A carbon arc to create heat. It even looks dangerous.

Can you imagine the WorkCare premiums?

 

  1892

Electrical resistance used to heat the soleplate.

1920's

First irons with a thermostat to regulate the temperature.

1939

E.P.Schreyer patents the iron steam chamber.

 

The credit for the invention of the steam iron however, goes to Thomas Sears in the early 1950's.

Mothers Day gift 2011

About Osca - Osca gifts.

Hot on the heels of Easter comes Mothers Day in 2011.  It has been a tradition at Osca for 25 years to give our customers a small gift for Mothers Day and a week from the first Sunday in May we had no gifts.

Panic...

As it happens, this year Easter and Mothers Day were just over a week apart and it wasn't until we had all the easter eggs packed that we realised we had forgotten all about Mothers Day.

Not that we are always ready on time :) Last year we fixed a similar problem by high tailing it to Chocolate Box and ordering a hundred chocolate hearts. It is getting harder each year to come up with something unique so that we don't repeat our selves and don't exceed our budget by too much.

In desperation we visited our mate Gary and as if he knew we were going to call on him, he had the perfect gifts. Fragrant reed diffusers. Already packed in stylish slender boxes, it was just a matter of tying and curling some nice ribbon and adding a little Osca card. Come Sunday night, a day before we needed to start distributing we were ready with all the gifts wrapped and packed. Close, but done.  Now we hope our customers will like them :)

Wrapping this years Mothers day presents was easy as they already came in stylish little boxes. So just a little ribbon and an "Osca card to say "Thank you for your custom".

It always puts a smile on a customer's face when they spy a little gift in their deliverd basket of ironing,

and this is what the diffuser looks like out of the box.

UFO over Melbourne ?

Thursday night on the evening run, what is that streaking across the sky ?

Looking west from Burke Road railway crossing near the Monash freeway.

Most likely a plane, would that make it an IFO ?

Views on the run

A mixture of fog and afternoon traffic smog with the sun just having set makes for a magical silhouette. This moment was snapped while waiting for the lights to change at the intersection of Canterbury and Burke roads earlier this week. A couple of seconds... and it is time to move on with the rest of the run.

Easter gift 2011

Chocolate Easter eggs. A small gift for all customers who have used our services in the week coming up to Easter. What can I say, It is a tradition and the look on children's faces when they spy Easter eggs in mommy's ironing basket is priceless :)

With a little persuasion, we managed to talk Easter bunny into parting with some Easter chocolates.

 

 

 

 

Each basket contained a small gift.

Easter logo.