As a core control component in vacuum systems, the innovative internal structure of the vacuum integrated valve is crucial for reducing gas leakage and improving sealing reliability. By optimizing the sealing structure design, improving material selection, enhancing dynamic sealing performance, simplifying fluid channels, integrating intelligent monitoring modules, optimizing valve body connections, and improving anti-contamination capabilities, the vacuum integrated valve can achieve efficient and stable sealing performance under complex operating conditions.
The sealing structure is the core of the vacuum integrated valve. Traditional designs often rely on a single sealing ring or planar seal, which is prone to leakage due to wear, aging, or pressure fluctuations. Modern innovations employ composite sealing structures, such as combining a metal elastic sealing ring with a rubber sealing ring. The rigid support of the metal ring and the flexibility of the rubber ring create a double sealing barrier. Furthermore, self-tightening sealing technology uses medium pressure to drive the sealing surfaces to fit tightly; the higher the pressure, the more reliable the seal, especially suitable for high-pressure or fluctuating conditions. Some designs also incorporate magnetic sealing elements, using magnetic force to enhance the fit of the sealing contact surfaces, further reducing the risk of leakage.
Material selection directly affects the durability and adaptability of the seal. Traditional rubber seals are susceptible to aging due to temperature and chemical media, while new sealing materials such as fluororubber and perfluoroether rubber possess superior high-temperature resistance and corrosion resistance, allowing for long-term use in extreme environments. Metal seals utilize high-strength materials such as stainless steel and titanium alloys, with precision machining ensuring a sealing surface roughness of less than 0.2μm to reduce gas molecule penetration. Some designs also incorporate nano-coating technology, forming a dense protective layer on the sealing surface to enhance wear resistance and corrosion resistance, extending seal life.
During the opening and closing process of a vacuum integrated valve, relative movement exists between the sealing surfaces, which can easily lead to wear or jamming due to friction. Dynamic sealing innovations address this issue by optimizing the design of the moving parts. For example, using low-friction polytetrafluoroethylene (PTFE) as a guide sleeve reduces valve stem movement resistance; or designing a ball bearing support structure converts sliding friction into rolling friction, reducing wear rate. Furthermore, the resilient valve seat design provides cushioning when the valve closes, preventing hard impact damage to the sealing surface while ensuring uniform pressure distribution and improving sealing reliability.
Simplifying and optimizing fluid channels reduces gas stagnation and turbulence, thereby lowering the risk of leakage. Traditional valves often contain multiple right-angle bends or narrow passages, easily creating dead zones in the airflow and increasing the probability of leakage. Modern designs optimize channel shapes through fluid dynamics simulations, employing rounded transitions or gradually expanding/contracting structures to ensure smooth airflow and reduce pressure loss and eddy current generation. Some integrated valves also integrate multiple functional modules (such as filtering, regulation, and shut-off) into a single valve body, shortening pipeline connection lengths and reducing potential leakage points.
The integration of intelligent monitoring modules enables vacuum-integrated valves to perform real-time self-checks. Through built-in pressure sensors, displacement sensors, or leakage detection elements, the valve can monitor the sealing status, opening and closing positions, and system vacuum, and immediately alarm or automatically take protective measures when a leak occurs. For example, when an abnormal drop in sealing pressure is detected, the valve can automatically close and lock to prevent further gas leakage; or it can upload leakage information to the control system via a wireless communication module to achieve remote monitoring and predictive maintenance.
The connection method between the valve body and the pipeline directly affects the reliability of the seal. Traditional flange connections require bolt tightening, which is prone to leakage due to uneven installation torque or gasket aging. Modern innovations employ clamp-type quick connections or welded integrated structures, reducing the number of connections and the risk of leakage. Clamp connections provide uniform sealing pressure through elastic retaining rings, are easy to install, and are reusable; welded connections form a permanent seal through molten metal, suitable for high-pressure or high-temperature conditions. Some designs also incorporate vacuum grease or sealant as auxiliary sealing methods to fill tiny gaps and improve sealing performance.
Vacuum systems may contain particulate contaminants or condensate, which can easily clog valves or corrode sealing surfaces. Anti-contamination designs reduce the impact of contaminants by optimizing the internal structure. For example, a removable filter screen is installed at the air inlet to intercept large particulate impurities; or a beveled sealing structure is used, allowing condensate to drain along the bevel rather than stagnating on the sealing surface. Some valves are also designed with a self-cleaning function, removing deposits from the sealing surface through reverse purging or mechanical scraping, ensuring long-term sealing reliability.
