FSW Aluminum Sidewall Assembly for Leak-Free Cargo Containers

Solution Overview

Problem

Existing cargo container sidewall constructions face challenges in achieving structural integrity, lightweight design, aerodynamic appearance, and efficient manufacturing processes, particularly due to issues with riveting and adhesive bonding methods that result in defects, water and air leakage, and increased construction time and cost.

Innovation Solution

The use of Friction Stir Welding (FSW) technology to join narrow aluminum sheets and posts, forming a compact solid phase weld seam that enhances strength, reduces deformation, and eliminates the need for rivets or adhesives, resulting in a lightweight, rigid, and watertight sidewall construction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If riveting or adhesive bonding methods are used to join sheets and posts, then the sidewall can be constructed with available materials and processes, but the construction time increases, labor costs increase, and the exterior surface becomes rough and un-aerodynamic

Engineering Contradiction:

Improvemanufacturing process availabilityVSAvoidconstruction time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces mechanical fastening systems (rivets, adhesives) with friction stir welding, a thermomechanical process that joins aluminum sheets and posts through localized heating and stirring, eliminating the need for holes, fasteners, or curing time while achieving stronger joints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the physical state and properties of the aluminum materials during joining by applying controlled heat and mechanical stirring, transforming the materials from solid to a softened state and back, creating a metallurgical bond that eliminates surface protrusions and achieves aerodynamic smoothness

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If riveting holes are punched into sheets and posts for assembly, then the components can be joined together, but water leakage and air flow through rivet holes occur

Engineering Contradiction:

Improveassembly capabilityVSAvoidsealing performance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces mechanical fastening systems (rivets, adhesives) with friction stir welding, a thermomechanical process that joins aluminum sheets and posts through localized heating and stirring, eliminating the need for holes, fasteners, or curing time while achieving stronger joints

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the physical state and properties of the aluminum materials during joining by applying controlled heat and mechanical stirring, transforming the materials from solid to a softened state and back, creating a metallurgical bond that eliminates surface protrusions and achieves aerodynamic smoothness

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If narrow aluminum sheets are used instead of wider sheets, then material availability increases and cost decreases, but the number of sheets required increases and construction complexity increases

Engineering Contradiction:

Improvematerial availabilityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent merges multiple narrow aluminum sheets and posts into a unified, integrated structure through friction stir welding, creating continuous weld seams that join components edge-to-edge or with minimal overlap, eliminating the need for numerous separate fastening operations and reducing overall assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

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

FSW technology improves the structural integrity and sealing of cargo container sidewalls, reduces labor and production time, and provides a refined, aerodynamic appearance while minimizing defects and leakage, thus enhancing the overall performance and manufacturing efficiency of the sidewall construction.

Implementation Method 1

Friction-stir-welded sheet-and-post sidewall

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

the sheets are placed under the posts and jointed tightly together through FSW. With the high-speed spinning of the stirring pin, the post and sheet melt and form into a compact solid phase weld seam

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11701737B2Friction-stir-welded sheet-and-post sidewall

Publication Date: 2023.07.18 QINGDAO CIMC REEFER TRAILER

AI summary

The disclosed wall includes several narrow aluminum sheets and posts that are Friction Stir Welded (FSW) into a sidewall. The length of the wall is the summation of the narrow sheets' width, and the walls width is the narrow sheets' length. Several aluminum posts are spaced along the wall's length direction in order to improve the stiffness and strength of the wall. When welding the aluminum sheets and posts together, the sheets are placed under the posts and jointed tightly together through FSW. With the high-speed spinning of the stirring pin, the post and sheet melt and form into a compact solid phase weld seam under the extrusion of the welding head. When welding two aluminum sheets and one post together, the two sheets are placed edge-to-edge or slightly overlapped. The post is then placed over the sheet joint and the stir-welding head melts portions of the post and the two sheets simultaneously.