Seam Guide Vacuum Extraction for Clean Roll-Formed Aluminum Tubes

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Solution Overview

Problem

Manufacturing small diameter aluminium tubes with low internal contamination levels is challenging due to high particle emission during high frequency welding, which exceeds the cleanliness limits required for HVAC&R applications.

Innovation Solution

A seam guide assembly and vacuum extraction system are integrated into a welded tube roll forming apparatus to guide and maintain strip edges during welding, coupled with a back flushing device to remove internal particles using vacuum and gas flow, ensuring effective contamination removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high frequency welding is used to manufacture aluminium tubes, then welding efficiency and productivity are improved, but internal particle contamination increases beyond acceptable limits

Engineering Contradiction:

Improvewelding efficiencyVSAvoidinternal particle contamination

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts harmful particles from the tube interior during the welding process by introducing a vacuum extraction system with suction nozzles positioned to remove particles generated during high frequency welding, thereby maintaining both high productivity and low contamination levels

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent introduces an intermediary vacuum extraction system between the welding coil and the tube interior, using suction nozzles and vacuum sources to mediate the removal of particles generated during welding, allowing high frequency welding to proceed efficiently while preventing particle accumulation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If small diameter tubes are manufactured to meet HVAC&R applications, then system efficiency and compactness are improved, but manufacturing difficulty and contamination control become more challenging

Engineering Contradiction:

Improvetube diameterVSAvoidmanufacturing difficulty

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The patent applies local quality by positioning vacuum extraction nozzles at specific locations within the tube interior and adjusting their orientation to effectively remove particles from small diameter tubes, where particle removal dynamics differ from larger tubes

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent changes operational parameters including vacuum pressure, nozzle positioning, and extraction timing to optimize particle removal in small diameter tubes, adapting the manufacturing process to the specific geometric constraints of small tube dimensions

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If aluminium tubing is used as an alternative to copper tubing for cost reduction, then material cost is reduced, but achieving required cleanliness standards becomes difficult

Engineering Contradiction:

Improvematerial costVSAvoidcleanliness standard compliance

Core Design Contradiction:

Loss of substanceVSManufacturing precision

Solution Approach 1:

The patent performs preliminary particle removal during the welding process itself by activating vacuum extraction before and during welding operations, preventing particle accumulation that would otherwise compromise cleanliness standards in cost-effective aluminium tubes

Inventive Principle:

Principle #10Preliminary action

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

The system enables the production of high-quality, low-contamination aluminium tubes with diameters of 20 mm or less, meeting stringent cleanliness standards for HVAC&R applications by effectively removing internal particles during the manufacturing process.

Implementation Method 1

a vacuum extraction section configured to extract solid particles produced inside the tube during the high frequency induction welding of the tube edges

Methodology Applied

Scientific EffectVacuum: Vacuum

Implementation Method 2

a welding section comprising a seam guide assembly, a high frequency induction weld coil and a pair of weld rollers and is configured to weld together the longitudinal edges

Methodology Applied

Scientific EffectHigh frequency induction welding: Electromagnetic Induction

Data Source

PatentUS12528108B2Manufacture of roll formed tubes

Publication Date: 2026.01.20 HYDRO EXTRUDED SOLUTIONS AS

AI summary

A seam guide assembly configured to maintain the longitudinal edges of a metal strip in position before welding in a welding section of a welded tube roll forming apparatus, the seam guide assembly having a front seam guide tip component, a through channel being provided in the holder, the channel having an inlet opening located on said first side of the holder, adjacent the front seam guide tip component, and an outlet opening located on a second side of the holder, the outlet opening being configured to connect to a vacuum source; a welded tube roll forming apparatus having a vacuum extraction section configured to extract solid particles produced inside the tube during the high frequency induction welding of the tube edges, and being located in the apparatus at a position where the where the edges of the roll formed tube have not yet been welded together; and related method.