Thin Aluminum Soleplate Assembly for Lower-Cost Iron Bases
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Solution Overview
Problem
Existing soleplates for ironing devices, particularly electric steam irons, face challenges with high manufacturing costs and complexity due to the use of thick and expensive stainless steel or aluminum sheets, which require precise processing and assembly.
Innovation Solution
A soleplate design featuring a thin aluminum sheet (0.35 mm to 0.8 mm thick) that is plastically deformed to fit around the edge of a cast aluminum base body, allowing for a form-fitting connection and surface treatment before attachment, reducing material usage and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thick aluminum plate (1.2 mm to 2.5 mm) is used as the soleplate, then the structural strength is improved, but the manufacturing complexity and cost increase due to precise embedding and assembly requirements
Solution Approach 1:
The patent uses a thin aluminum sheet (0.35 mm to 0.8 mm) instead of a thick rigid plate. The thin sheet is plastically deformed around the base body edge to create a form-fitting connection, eliminating the need for precise embedding and complex assembly procedures while maintaining sufficient structural strength for soleplate application.
Solution Approach 2:
The invention changes the thickness parameter of the aluminum soleplate from the conventional 1.2-2.5 mm down to 0.35-0.8 mm. This parameter change fundamentally alters the manufacturing approach from precise embedding to plastic deformation and form-fitting connection, reducing manufacturing complexity while maintaining adequate strength.
2Ease of manufacture
If a thin aluminum sheet (0.35 mm to 0.8 mm) is used, then the manufacturing cost and complexity are reduced, but the structural strength may be compromised
Solution Approach 1:
The thin aluminum sheet is plastically deformed around the edge of the base body, creating a curved, form-fitting connection. This curvature distributes stresses more effectively and creates a mechanical interlock that compensates for the reduced material thickness, maintaining structural strength despite using thinner material.
Solution Approach 2:
The soleplate forms a composite structure combining the thin aluminum sheet with the base body through form-fitting connection. The aluminum sheet is plastically deformed around the base body edge, creating a mechanically integrated assembly where the combination of thin sheet and base body provides sufficient overall strength.
3Reliability
If plastic deformation is applied to the aluminum sheet edge, then the connection to the base body is improved, but the surface appearance may be impaired
Solution Approach 1:
The plastic deformation is applied locally only to the edge region of the aluminum sheet that contacts the base body, while the main sliding surface retains its original smooth appearance. This localized application of deformation maintains connection reliability at the edge without impairing the aesthetic and functional quality of the visible sliding surface.
Solution Approach 2:
The aluminum sheet is functionally segmented into two regions: the edge region undergoes plastic deformation for reliable connection to the base body, while the sliding surface region maintains its original smooth finish for aesthetic and functional purposes. This segmentation allows different quality requirements to be met in different areas.
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 approach significantly reduces manufacturing costs, simplifies the production process, and allows for various surface treatments and appearances without post-processing, enabling a cost-effective and versatile soleplate solution.
Implementation Method 1
an edge area of the aluminum sheet is plastically deformed, in particular folded or rolled, and is thus connected to the side edge in a form-fitting manner
Data Source
Figure 1
Figure 2
AI summary
Iron base (2) of an ironing device, in particular an electric steam iron or an electric steam ironing station, comprising an iron base substrate (4) and a base plate (12) made of aluminum and disposed at the bottom (4a) of the substrate (4) and connected thereto. The base plate (12) is made from an aluminum sheet (20) having a thickness (T) of 0.35 mm to 0.8 mm, in particular about 0.4 mm; and the substrate (4) comprises a lower lateral edge (18) about which an edge area (20c) of the aluminum sheet (20) is plastically deformed and thus connected in shape-locked fashion to the lateral edge (18). The invention also relates to an ironing device comprising such an iron base (2) and to a method for manufacturing such an iron base (2).