The study on the size scaling characteristics of <scp>DLV</scp> ‐ <scp>SAR</scp> microchannel mixers

Abstract This study builds on the DLV‐SAR micromixer proposed by our research team and uses water as the working fluid to investigate the effects of microchannel dimensional scaling and channel‐length extension (by connecting micro‐mixer units) on flow velocity, mixing performance, and pressure drop. Experimental measurements are used to quantitatively validate the pressure drop. One‐dimensional scaling increases the hydraulic diameter to 0.96 mm 2 , reducing pressure loss but lowering the mixing index to below 85%, while a channel depth of 1200 μm yields the highest overall index of 1.42. Two‐dimensional scaling significantly increases volumetric flow but degrades mixing efficiency, with a peak flow rate of 175 mm 3 /s at a channel diameter of 1000 μm. By connecting five micromixing units with an 800 μm diameter in series, a volumetric flow of 234 mm 3 /s and a maximum mixing index of 99.61% are achieved. These results provide theoretical support for the design of high‐throughput industrial micromixers.