How are you storing the iron? I've never had an iron cord curl up, but I HAVE had the cords on other appliances curl. It seems to happen on cords that get wrapped around something in preparation for storage. The worst one is my husband's CPAP machine. He travels a lot and takes his CPAP with him. When he packs it, he wraps the cord around his hand and stuffs it in the bag. It is really, really twisted.