Custom Silicone Valve Solution for Liquid Dishwashing Brushes: Enhancing Product Performance and Reducing Leakage

Background

A globally recognized leader in household cleaning products, known for its eco-friendly innovations, faced a critical challenge with its dishwashing brushes. Despite a strong presence in over 50 countries, the brand was struggling with leakage issues in its brushes after they were loaded with cleaning agents. This leakage not only created a frustrating user experience but also escalated warranty claims and after-sales costs. YEJIA, as the leading manufacturer of leak-proof custom silicone valves, was selected to provide a tailored solution to address these issues.

Challenge

The primary issue was the leakage of cleaning fluid when the brush was inverted, causing frustration among consumers and hindering the product's reliability. This leakage issue not only affected product functionality but also led to an inconsistent user experience and higher warranty claims. In addition, there were challenges related to inconsistent wall thickness and inaccurate dispensing angles that impacted the efficiency and performance of the silicone dispensing valve.

Solution

YEJIA tackled the leakage problem by utilizing advanced Liquid Silicone Rubber (LSR) high-precision injection molding technology and a specially formulated, highly elastic silicone material. A detailed analysis of material properties, as well as the thickness of the product's top and sidewalls, led to an optimized sealing structure that successfully prevented leakage. The silicone flow control valve was engineered to withstand continuous inversion for 7 days and 24 hours without leaking, thus significantly improving the product’s durability and user experience.

Key Innovations

* Leakage Prevention: By fine-tuning the material formulation and mold design, YEJIA ensured a robust sealing system. Rigorous testing, including repeated verifications of different hardness materials, helped refine the sealing structure, resulting in zero leakage during extended periods of inversion.

* Wall Thickness Consistency: The existed silicone valves suffered from significant variation in wall thickness, leading to inconsistencies in sealing and product lifespan. YEJIA's solution involved precision mold design and the use of advanced molding equipment, with tight tolerances of ±0.01mm. This controlled wall thickness variation, keeping it within ±0.05mm, significantly enhanced the valve's consistency and sealing performance.

* Accurate Dispensing Angle Control: Another issue was the inconsistency in the liquid dispensing direction when the brush was pressed. YEJIA solved this by implementing high-precision cutting and automated punch-cutting technology. This ensured that the cross slit's offset tolerance was maintained, allowing for a consistent ±15° directional dispensing angle that adhered to ergonomic principles, improving both functionality and user experience.

* Reduced Residual Liquid: A major consumer complaint was the 20% residual liquid that could not be dispensed from the brush. YEJIA's innovative design of the ultra-thin sidewalls and elastic cone-shaped valve body created a negative pressure siphon effect upon rebound. This breakthrough design reduced the residual liquid rate to under 2%, addressing waste concerns and enhancing customer satisfaction.

* Effective Defect Rate Control: Early production stages faced higher defect rates, leading to inefficiencies and wasted resources. YEJIA collaborated closely with the client to define stringent product quality standards. Additionally, the introduction of an Automated Optical Inspection (AOI) system allowed for 100% product inspection, ensuring that each silicone cross slit valve met the customer’s assembly requirements and reducing defect rates significantly.

Results

YEJIA's custom silicone valve solution successfully solved the client's leakage issue, as well as addressing problems such as uneven wall thickness, dispensing angle deviation, high residual liquid, and high defect rates. The solution not only enhanced product functionality and durability but also reduced operational costs, contributing to improved customer satisfaction and long-term brand loyalty.

YEJIA has set a new standard for performance and reliability with the custom silicone valves. Our advanced technology and precise design ensure that we deliver high-quality, durable solutions that improve product functionality and user experience. If you're looking for custom silicone valves factory, contact us today to see how we can enhance your product's performance.