The flow channel design of a vacuum integrated valve is one of the core factors affecting its performance, especially in applications requiring high vacuum or high flow rates. The rationality of the flow channel design directly determines the magnitude of pressure loss. Optimizing the flow channel design aims to reduce energy loss of the fluid as it passes through the valve, thereby improving system efficiency and reducing energy consumption. This requires comprehensive consideration from multiple dimensions, including flow channel geometry, surface roughness, layout rationality, and manufacturing processes.
The geometry of the flow channel has the most significant impact on pressure loss. Complex flow channel structures, such as too many right-angle turns or narrow cross-sections, can lead to eddies and localized energy loss during fluid flow. Replacing right-angle turns with rounded corners can effectively reduce energy loss at bends, making the flow smoother. Furthermore, the expansion and contraction design of the flow channel must follow a gradual principle to avoid abrupt changes in flow velocity caused by sudden changes in cross-sectional area, which would increase pressure loss. A reasonable flow channel geometry design can significantly reduce pressure loss along the flow path and localized pressure loss.
The surface roughness of the flow channel is another key factor. Friction between the fluid and the channel wall consumes energy; the rougher the surface, the greater the frictional resistance and the more significant the pressure loss. Therefore, in material selection, materials with smooth surfaces and corrosion resistance, such as stainless steel or specially treated alloys, should be prioritized. For selected materials, surface treatments such as polishing and electroplating can further reduce roughness, thereby reducing frictional losses between the fluid and the wall.
The layout design of the flow channel is equally important. An unreasonable layout can lead to uneven fluid distribution in branch channels, with some channels experiencing excessively high pressure while others have insufficient flow, resulting in increased overall pressure loss. Optimizing the channel layout to ensure even fluid distribution to each branch can effectively prevent localized high pressure. For example, in multi-port vacuum integrated valves, using a symmetrical layout or optimized path design based on fluid dynamics simulation can significantly improve fluid distribution efficiency.
The manufacturing process also significantly impacts flow channel performance. Traditional subtractive manufacturing processes may have precision limitations when machining complex flow channels, while additive manufacturing technology provides greater freedom in flow channel design. Additive manufacturing enables the creation of flow channel structures that are difficult to achieve with traditional processes, such as smooth three-dimensional transitions or internally reinforced structures. This reduces material usage and pressure loss while maintaining strength. Furthermore, additive manufacturing supports customized designs, allowing for the creation of optimal flow channel structures tailored to specific application scenarios.
In the flow channel design of vacuum integrated valves, fluid characteristics and operating conditions must also be considered. For example, when handling high-viscosity fluids, the flow channel diameter should be appropriately increased to reduce frictional resistance; while in scenarios requiring rapid response, the flow channel length needs to be optimized to reduce pressure loss due to fluid inertia. By combining numerical simulations and experimental verification, more targeted flow channel design solutions can be developed for different application scenarios.
Optimizing the flow channel design of vacuum integrated valves is a systems engineering project involving multidisciplinary knowledge. By improving geometry, reducing surface roughness, optimizing layout design, and employing advanced manufacturing processes, pressure loss can be significantly reduced and valve performance improved. In the future, with the continuous advancement of materials science and manufacturing technology, the flow channel design of vacuum integrated valves will become more refined and intelligent, providing more efficient and reliable solutions for high vacuum systems.
