Composite Ironer Bed Plates for Low Friction and Corrosion Resistance
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Solution Overview
Problem
Existing ironer beds face challenges with smudging, high friction, and corrosion resistance, particularly when using stainless steel, which increases friction and is prone to galvanic corrosion when used in combination with other materials.
Innovation Solution
A combination of a non-alloy or low-alloy steel ironing plate and a thinner austenitic stainless steel dimple plate, where the ironing plate is sanded for improved sliding and the dimple plate is made thinner for better heat passage, joined using methods like laser welding without filler material, providing cathodic protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stainless steel ironing plate is used, then corrosion resistance is improved, but friction increases and smudging occurs
Solution Approach 1:
The ironer bed combines two different steel materials: a non-alloy or low-alloy steel ironing plate (providing low friction and good sliding properties) with a austenitic stainless steel dimple plate (providing corrosion resistance). This composite construction allows each material to perform its optimal function without the drawbacks of using either material alone.
2Force
If a non-alloy or low-alloy steel ironing plate is used, then friction is reduced and sliding is improved, but corrosion resistance deteriorates
Solution Approach 1:
The ironer bed combines two different steel materials: a non-alloy or low-alloy steel ironing plate (providing low friction and good sliding properties) with a austenitic stainless steel dimple plate (providing corrosion resistance). This composite construction allows each material to perform its optimal function without the drawbacks of using either material alone.
3Strength
If a thicker plate is used for the ironing plate, then structural rigidity is improved, but heat transmission capability deteriorates
Solution Approach 1:
The ironer bed uses a thicker non-alloy or low-alloy steel ironing plate for structural rigidity and a thinner austenitic stainless steel dimple plate for heat transmission. The thinner stainless plate allows better heat transmission while the thicker ironing plate provides the necessary structural support.
4Reliability
If stainless steel plates are used in combination with other materials, then corrosion resistance is improved, but galvanic corrosion increases
Solution Approach 1:
The invention specifies using a non-alloy or low-alloy steel ironing plate in combination with a austenitic stainless steel dimple plate. This specific material parameter combination, joined by welding without filler material, creates a galvanic couple where the non-alloy or low-alloy steel provides cathodic protection to the stainless steel, preventing galvanic corrosion of the dimple plate.
5Strength
If the dimple plate is made thicker, then structural strength is improved, but heat passage formation and cathodic protection deteriorate
Solution Approach 1:
The invention specifies using a thinner austenitic stainless steel dimple plate (0.5-2.0 mm) compared to conventional thicknesses. This thinner plate allows better heat passage formation and enables the non-alloy or low-alloy steel ironing plate to provide effective cathodic protection, while still maintaining sufficient structural strength for the application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces smudging, friction, and corrosion while maintaining effective heat transfer and structural integrity, preventing galvanic corrosion and enhancing durability in steam environments.
Implementation Method 1
the one facing away from the ironer roller, being a stainless steel plate which is thinner than the former one plate. By selecting precisely this combination of plate materials and plate thicknesses, all of the desired properties are obtained.
Implementation Method 2
the ironer bed is heated by means of steam or heat transmission oil to 150-240° C
Implementation Method 3
through that process, a surface texture is accomplished where, in standard ironing processes, the textile slides easily across the ironing surface
Data Source
AI summary
An ironer bed comprising a pair of metal plates (6, 7) that are joined by welding in two layers such that, between the plates, passages (5) are provided for a heat medium; and are configured such that they are capable of partially enclosing an ironer roller (12-15). The plate (7) that faces towards the ironing roller (12-15) is made of non-alloy or low-alloy steel; and the plate (6) that faces away from the ironer roller (12-15) is a plate of stainless steel which is thinner than the former plate.