Ultrasonic Welding Machine for Mobile Chargers
Ultrasonic welding is well suited to joining the plastic housings of mobile phone chargers and adapters. It bonds the upper and lower thermoplastic shells without adhesives or screws, creating a strong, tamper-resistant joint.
Recommended starting specifications for a typical small mobile charger:
Parameter Recommended
Frequency 20 kHz
Power 1500–2000 W
Generator Digital preferred
Welding mode Time + Energy mode
Actuation Pneumatic
Air pressure ~2–6 bar adjustable
Horn Custom-designed to charger profile
Fixture Custom rigid bottom nest
Typical plastics ABS, PC, PC/ABS
Power supply 220–230 V, single phase
Commercial charger-welding machines commonly use 20 kHz systems rated at 1, 800–2, 000 W, with current models available in both configurations.
Most important part: charger body design
A reliable weld depends on more than the machine. Joint geometry, the energy director, horn, and fixture are equally critical. For a charger shell, a small triangular energy director is typically placed around the perimeter of the mating surface. During welding, the horn clamps the shells while 20 kHz vibrations concentrate heat at the energy director.
For small charger housings, 20 kHz is generally preferable to 15 kHz. A 15 kHz, 2, 600 W system is better suited to larger or thicker adapter housings that require greater vibration amplitude.
If you plan to develop a mobile-charger welding machine, Dsonik can help design the complete system: 20 kHz generator → transducer → booster → horn → pneumatic press → charger fixture, including recommended horn dimensions and energy-director geometry.
Dsonik has vide range of ultrasonic plastic welding machine:
DX-Eco series - low price standard analog welding system
DX-1 series – Standard analog/digital ultrasonic welder in square column
DX – 2 Series – High end Digital ultrasonic welder in square column
DX – Servo Easy – Entry level Servo control ultrasonic welder in square column
DX – Servo High End – Advance level Servo control ultrasonic plastic welding machine
DX – Euro – European standard Digital and Servo control high end ultrasonic plastic welding machine
