CN114447999A - Housing, charger and charger manufacturing method - Google Patents

Abstract

The embodiment of the application provides a shell, a charger and a charger manufacturing method, wherein the shell comprises an upper shell and a lower shell; the lower shell includes a first portion having first and second abutting surfaces; the upper shell is provided with an ultrasonic welding structure, the ultrasonic welding structure can form a first welding surface and a second welding surface which are adjacent, the first welding surface is welded with the first surface, and the second welding surface is welded with the second surface, so that the upper shell is fixedly connected with the lower shell. In the embodiment of the application, the welding strength of ultrasonic welding is carried out with strengthening epitheca and inferior valve through setting up the first face of weld that adjoins with the second face of weld to can reduce the welding area of second face of weld, and then reduce the thickness of casing.

Description

Housing, charger and charger manufacturing method

Technical Field

The present disclosure relates to electronic technologies, and in particular, to a housing, a charger, and a method for manufacturing a charger.

Background

With the development of communication technology, electronic devices such as smart phones are becoming more and more popular, and wearable devices such as smart watches and smart bracelets are also becoming more and more popular. In the use of intelligent wrist-watch and intelligent bracelet, need use the charger that corresponds to charge it when its electric quantity is lower. In the related art, the housing of the charger is generally welded to the upper housing and the lower housing by ultrasonic welding. However, the conventional ultrasonic welding requires a large welding area of the welding surface to ensure the welding strength, so that the charger housing is thick, which is not favorable for the miniaturization of the charger.

Disclosure of Invention

The embodiment of the application provides a shell, a charger and a charger manufacturing method, which can reduce the thickness of the shell of the charger.

An embodiment of the present application provides a housing, the housing includes:

a lower shell including a first portion having first and second abutting surfaces; and

the upper shell, the upper shell is provided with the ultrasonic bonding structure, the ultrasonic bonding structure can form first face of weld and the second face of weld that adjoins, first face of weld with first surface bonding, the second face of weld with the second surface bonding, so that the upper shell with inferior valve fixed connection.

The embodiment of the present application provides a charger again, the charger includes casing and charging element, the charging element sets up in the casing, the casing be as above-mentioned the casing.

The embodiment of the present application further provides a charger manufacturing method, where the charger manufacturing method includes:

providing an upper shell and a lower shell, wherein the lower shell comprises a first part and a second part, the first part is provided with a first surface and a second surface which are adjacent, the second part is arranged in a coplanar manner with one part of the second surface and protrudes out of the second surface, and the upper shell is provided with an ultrasonic welding structure;

pressing the upper case and the lower case to compress the ultrasonic welding structure to the second surface;

ultrasonically treating the ultrasonic welded structure to vibrate the ultrasonic welded structure at a high frequency to frictionally generate heat with the second surface;

and after the ultrasonic welding structure is heated and melted, removing the ultrasonic waves and continuously applying pressure to the upper shell and the lower shell, so that the ultrasonic welding structure forms a first welding surface welded with the first surface and a second welding surface welded with the second surface.

In the embodiment of the application, the casing comprises epitheca and inferior valve, and the first part of inferior valve has the first surface and the second surface that adjoin, and the epitheca is provided with ultrasonic bonding structure, can form after the welding with first surface welded first face of weld and with second surface welded second face of weld, through setting up the first face of weld that adjoins with the second face of weld in order to strengthen ultrasonic bonding's welding strength to can reduce the welding area of second face of weld, and then reduce the thickness of casing.

Drawings

In order to more clearly illustrate the technical solutions in the embodiments of the present application, the drawings used in the description of the embodiments will be briefly introduced below.

Fig. 1 is a schematic structural diagram of a charger according to an embodiment of the present application.

Fig. 2 is a schematic structural diagram of a housing in the charger shown in fig. 1.

Fig. 3 is a schematic structural view of the housing shown in fig. 2 before welding.

Fig. 4 is a first cross-sectional view of the housing of fig. 2 taken along the line P1-P1.

Fig. 5 is a first cross-sectional view of the housing of fig. 3 taken along the line P2-P2.

Fig. 6 is a partially enlarged view of a portion a in fig. 4.

Fig. 7 is a partially enlarged view of a portion B in fig. 5.

Fig. 8 is a second cross-sectional view of the housing of fig. 2 taken along the line P1-P1.

Fig. 9 is a second cross-sectional view of the housing of fig. 3 taken along the line P2-P2.

Fig. 10 is a partially enlarged view of a portion C in fig. 8.

Fig. 11 is a partially enlarged view of a portion D in fig. 9.

Fig. 12 is another partial enlarged view of a portion C in fig. 8.

Fig. 13 is a further enlarged partial view of portion C of fig. 8.

Fig. 14 is a flowchart of a method for manufacturing a charger according to an embodiment of the present disclosure.

Fig. 15 is another flowchart of a method for manufacturing a charger according to an embodiment of the present disclosure.

Detailed Description

In order to make the technical solutions better understood by those skilled in the art, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. It is to be understood that the embodiments described are only a few embodiments of the present application and not all embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present application.

Embodiments of the present application provide a housing, charger, and charger manufacturing method that may be a charger for a wristwatch device, a hanging device, an earphone or earpiece device, a device embedded in eyeglasses, or other device worn on the user's head or other wearable or miniature device, or may be a charger for a laptop computer, a computer monitor containing an embedded computer, a tablet computer, a cellular telephone, a media player, or other handheld or portable electronic device, a computer display that does not contain an embedded computer, a gaming device, a navigation device, an embedded system (such as a system in which an electronic device with a display is installed in a kiosk or automobile), a device that implements the functionality of two or more of these devices, or other electronic devices. In the embodiment of the present application, a charger is taken as an example of a smart watch, but the specific use scenario of the charger is not limited in the embodiment of the present application.

Referring to fig. 1, fig. 1 is a schematic structural diagram of a charger according to an embodiment of the present disclosure. The charger 10 may include a housing 20, a charging element 30, and a charging cord 40. Wherein the housing 20 forms an outer contour of the charger 10, the charging element 30 is an electronic device related to charging in the charger 10, the charging element 30 is disposed in the housing 20, and the charging wire 40 is used for electrically connecting the charging element 30 with an external power source. It will be appreciated that the charger 10 may also include other components, such as a waterproof component, etc., and that FIG. 1 is merely exemplary.

Referring to fig. 2 and 3, fig. 2 is a schematic structural diagram of a housing in the charger shown in fig. 1, and fig. 3 is a schematic structural diagram of the housing shown in fig. 2 before welding. The housing 20 may include a lower case 210 and an upper case 220, the upper case 220 is covered on the lower case 210 by ultrasonic welding technology, and a receiving space is formed therebetween for receiving the charging element 30 and a part of the charging cord 40 of the charger 10 and other components.

It should be noted that ultrasonic welding is a rapid, clean and effective assembly process in which high-frequency vibration waves are transmitted to the surfaces of two objects to be welded, and the surfaces of the two objects are rubbed with each other under pressure to form fusion between molecular layers. Methods for assembling thermoplastic fittings and some synthetic components are commonly used. The specific operation method is that current 50/60Hz electric frequency is converted into 20KHz or 40KHz high-frequency electric energy to be supplied to a converter through a transistor functional device, the converter converts the electric energy into mechanical vibration energy for emitting ultrasonic waves, a pressure regulating device transmits the converted mechanical energy to a welding head of an ultrasonic welding machine, the welding head directly transmits the mechanical vibration energy to a product to be pressed, so that the product to be pressed vibrates in high frequency, the product to be pressed vibrates in high frequency and rubs to generate heat energy to melt the pressing part of the product to be pressed, the vibration stops when a molten state substance reaches an interface of the product, and the melt can generate strong molecular bonds when a bonding surface is solidified by temporarily keeping the pressure, so that the product to be pressed is fused. The entire cycle of ultrasonic welding is usually completed in less than one second, but the weld strength is close to that of a complete piece of material.

Referring to fig. 4 to 7, fig. 4 is a first sectional view of the housing shown in fig. 2 taken along a direction P1-P1, fig. 5 is a first sectional view of the housing shown in fig. 3 taken along a direction P2-P2, fig. 6 is a partially enlarged view of a portion a in fig. 4, and fig. 7 is a partially enlarged view of a portion B in fig. 5. The lower case 210 forms a main profile of the charger 10, and at the same time, the lower case 210 may also serve as a protective case for the charging element 30 and other circuit structures of the charger 10, preventing the charging element 30 and other circuit structures of the charger 10 from being damaged due to a collision or a drop of the charger 10, or the like. The lower housing 210 may include a first portion 211, the first portion 211 having a first surface 2111 and a second surface 2112 that are adjacent. Here, the first surface 2111 may be an inner surface of the lower case 210, and the second surface 2112 may be an upper surface of the lower case 210, that is, a surface facing the upper case 220. It should be noted that the first surface 2111 is adjacent to the second surface 2112, which means that the first surface 2111 and the second surface 2112 have a common edge and are not in the same plane.

The lower case 210 may be formed by a side wall surrounding the periphery of the bottom wall. The sidewalls may be disposed perpendicular to the bottom wall or inclined to the bottom wall such that the lower case 210 forms a groove-like structure. The bottom wall of the lower case 210 may be rectangular or rounded rectangular, the bottom wall of the lower case 210 may also be circular or elliptical, and the bottom wall of the lower case 210 may also be in a shape similar to a racetrack with two sides being straight lines and two ends being semi-circles. The specific shape of the lower case 210 is not limited in the embodiments of the present application.

The lower case 210 may be made of non-metal materials such as plastic, resin, or acryl, and the lower case 210 may also be made of metal materials and non-metal materials, specifically, the metal may be made into a groove structure with a predetermined shape, and then a layer of non-metal is coated on the outer surface of the metal groove structure by injection molding. The specific material of the lower case 210 is not limited in the embodiment of the present application.

The upper case 220 is seated on the lower case 210 to seal the lower case 210. The upper case 220 may include a main body 221, and the main body 221 is provided with an ultrasonic welding structure 222. An ultrasonic welding structure 222 is provided around the edge of the body 221 for welding the upper case 220 to the lower case 210. As shown in fig. 5, the cross section of the ultrasonic welding structure 222 is a triangle, specifically, the cross section of the ultrasonic welding structure 222 may be a right triangle, the cross section of the ultrasonic welding structure 222 may also be an isosceles triangle, and the cross section of the ultrasonic welding structure 222 may also be a non-special triangle. The ultrasonic welding structure 222 shown in fig. 5 has a right-angled triangle shape in cross section, and the right-angled side of the ultrasonic welding structure 222 is adjacent to the outside of the lower case 210. It will be appreciated that the right angled sides of the ultrasonic weld structures 222 may also be adjacent the inside of the lower shell 210. The embodiment of the present application does not limit the specific shape of the ultrasonic welding structure 222.

The main body 221 of the upper case 220 may include only the bottom wall, and then the main body 221 has a plate-shaped structure. The main body 221 of the upper shell 220 may also include a bottom wall and side walls, and specifically, the main body 221 may be formed by the side walls surrounding the periphery of the bottom wall, and the side walls may be disposed perpendicular to the bottom wall or oblique to the bottom wall, so that the main body 221 also forms a groove-like structure. The bottom wall of the body 221 may be rectangular or rounded rectangular, the bottom wall of the body 221 may also be circular or elliptical, and the bottom wall of the body 221 may also be shaped like a playground track with straight lines on both sides and semi-circles on both ends. The specific shape of the main body 221 is not limited in the embodiments of the present application, but the shape of the bottom wall of the main body 221 should be consistent with the shape of the bottom wall of the lower case 210.

When the lower case 210 and the upper case 220 are ultrasonically welded, the first and second surfaces 2111 and 2112 of the lower case 210 and the ultrasonic welding structure 222 of the upper case 220 are melted by heat generated by friction due to high-frequency vibration, and the ultrasonic welding structure 222 is reshaped by the pressure of the first and second surfaces 2111 and 2112 to form a first welding surface 2221 welded to the first surface 2111 and a second welding surface 2222 welded to the second surface 2112. Compared with the case that the second welding surface 2222 is only opposite to the second surface 2112 of the upper shell 220, the embodiment of the present application further provides the first welding surface 2221 corresponding to the first surface 2111, so that the welding strength between the upper shell 220 and the lower shell 210 can be enhanced.

In some embodiments, the first surface 2111 or the second surface 2112 is provided with a concave-convex structure such that the first surface 2111 or the second surface 2112 is a concave-convex surface, thereby increasing the welding area between the first surface 2111 and the first welding surface 2221 or between the second surface 2112 and the second welding surface 2222. The first surface 2111 and the second surface 2112 may also each be provided with a rugged structure, so that the first surface 2111 and the second surface 2112 are both rugged surfaces, thereby increasing the welding area between the first surface 2111 and the first welding surface 2221 and the welding area between the second surface 2112 and the second welding surface 2222.

In the embodiment of the present application, the housing 20 is composed of the upper housing 220 and the lower housing 210, the first portion 211 of the lower housing 210 has the first surface 2111 and the second surface 2112 which are adjacent to each other, the upper housing 220 is provided with the ultrasonic welding structure 222, the first welding surface 2221 which is welded to the first surface 2111 and the second welding surface 2222 which is welded to the second surface 2112 can be formed after welding, and the welding strength of ultrasonic welding is enhanced by providing the first welding surface 2221 which is adjacent to the second welding surface 2222, so that the welding area of the second welding surface 2222 can be reduced, the thickness of the housing 20 is reduced, and the miniaturization of the charger 10 is facilitated.

Referring to fig. 8 to 11, fig. 8 is a second sectional view of the housing shown in fig. 2 taken along a direction P1-P1, fig. 9 is a second sectional view of the housing shown in fig. 3 taken along a direction P2-P2, fig. 10 is a partially enlarged view of a portion C in fig. 8, and fig. 11 is a partially enlarged view of a portion D in fig. 9. The lower case 210 further includes a second portion 212, the second portion 212 is disposed coplanar with a portion of the second surface 2111 of the first portion 211 that is not welded to the second welding surface 2222, and the second portion 212 protrudes from the second surface 2112, in other words, the second portion 212 is disposed on the second surface 2112 and protrudes from the second surface 2112, a portion of the second surface 2112 near the outer side of the lower case 210 is used for disposing the second portion 212, and a portion of the second surface 2112 near the inner side of the lower case 210 is used for welding to the second welding surface 2222.

The second portion 212 has a third surface 2123 and a fourth surface 2124 which are contiguous, wherein the third surface 2123 is also contiguous with the second surface 2112, in other words, one of two opposite sides of the third surface 2123 is common to the second surface 2112 and the other side is common to the fourth surface 2124. It should be noted that second surface 2112 is adjacent to third surface 2123, indicating that second surface 2112 and third surface 2123 share a common edge and are not in the same plane; third surface 2123 is contiguous with fourth surface 2124, indicating that third surface 2123 and fourth surface 2124 share a common edge and are not in the same plane.

The upper shell 220 has a fifth surface 2225 adjacent to the second welding surface 2222, and a gap 230 is formed between the fifth surface 2225 and the third surface 2123, that is, the gap 230 is formed between the upper shell 220 and the second portion 212, and the gap 230 is used for accommodating the ultrasonic welding structure 222 melted during ultrasonic welding. When the lower case 210 and the upper case 220 are ultrasonically welded, the first surface 2111 and the second surface 2112 of the lower case 210 and the ultrasonic welding structure 222 of the upper case 220 are melted by heat generated by friction due to high-frequency vibration, and the ultrasonic welding structure 222 is reshaped by the pressure of the first surface 2111 and the second surface 2112 to form a first welding surface 2221 welded to the first surface 2111 and a second welding surface 2222 welded to the second surface 2112, and the excess melted ultrasonic welding structure 222 overflows to the gap 230.

In some embodiments, the fifth surface 2225 of the upper case 220 is parallel to the third surface 2123 of the lower case 210, so that the slit 230 is a constant-width slit, i.e., the width of the slit 230 is equal everywhere, as shown in fig. 12, and fig. 12 is another partial enlarged view of the portion C in fig. 8. Wherein the width of the slit 230 is the width of the slit 230 in the direction perpendicular to the fifth surface 2225.

In other embodiments, the fifth surface 2225 of the upper case 220 is not parallel to the third surface 2123 of the lower case 210, such that the gap 230 is a gap with a non-constant width, and the distance between the fifth surface 2225 and the third surface 2123 gradually decreases from the second surface 2112 toward the fourth surface 2124, such that the gap 230 gradually narrows from the second surface 2112 toward the fourth surface 2124, as shown in fig. 13, which is a further partial enlarged view of a portion C in fig. 8. Wherein the width of the slit 230 is the width of the slit 230 in the direction perpendicular to the fifth surface 2225.

Compared to disposing the fifth surface 2225 parallel to the third surface 2123 to make the gap 230 a constant-width gap and disposing the fifth surface 2225 parallel to the third surface 2123 to make the gap 230 a narrow-width gap, the gap 230 can have a larger volume near the second surface 2112, so as to avoid the excessive melted ultrasonic welding structure 222 overflowing to the fourth surface 2124 during ultrasonic welding from affecting the appearance of the housing 20.

Referring to fig. 1, the lower case 210 further has a through hole 213. The through hole 213 is used for passing through the charging wire 40, so that a part of the charging wire 40 is located inside the housing 20 and a part of the charging wire is located outside the housing 20. The charging wire 40 located inside the housing 20 is electrically connected to the charging element 30 of the charger 10, and the charging wire 40 located outside the housing 20 is electrically connectable to an external power source, so that the charging element 30 of the charger 10 is electrically connected to the external power source through the charging wire 40.

In the embodiment of the present application, the housing 20 is composed of the upper housing 220 and the lower housing 210, the first portion 211 of the lower housing 210 has the first surface 2111 and the second surface 2112 which are adjacent to each other, the upper housing 220 is provided with the ultrasonic welding structure 222, the first welding surface 2221 which is welded to the first surface 2111 and the second welding surface 2222 which is welded to the second surface 2112 can be formed after welding, and the welding strength of ultrasonic welding is enhanced by providing the first welding surface 2221 which is adjacent to the second welding surface 2222, so that the welding area of the second welding surface 2222 can be reduced, the thickness of the housing 20 is reduced, and the miniaturization of the charger 10 is facilitated. In addition, the second portion 212 of the lower case 210 protrudes from the second surface 2112, so that a step is formed between the second portion 212 and the first portion 211, and a gap 230 is formed between the second portion 212 of the lower case 210 and the upper case 220 for accommodating an excessive melted ultrasonic welding structure 222 during ultrasonic welding, thereby preventing flash from being formed on the appearance surface of the lower case 210, and effectively improving the appearance expressive force of the housing 20.

The housing and the charger provided in the embodiment of the present application are explained below from the viewpoint of the manufacturing process of the charger 10.

Referring to fig. 14, fig. 14 is a flowchart of a method for manufacturing a charger according to an embodiment of the present application. The charger manufacturing method provided by the embodiment of the application comprises the following steps:

s101, providing an upper shell and a lower shell, wherein the lower shell comprises a first part and a second part, the first part is provided with a first surface and a second surface which are adjacent, the second part is arranged in a coplanar manner with one part of the second surface and protrudes out of the second surface, and the upper shell is provided with an ultrasonic welding structure.

In the embodiment of the present application, the upper shell and the lower shell may be made of non-metal materials such as plastic, resin or acrylic, the upper shell and the lower shell may also be made of metal materials and non-metal materials, specifically, the metal may be made into a predetermined shape, and then a layer of non-metal is coated on the outer surface of the metal structure by injection molding.

And S104, pressing the upper shell and the lower shell to press the ultrasonic welding structure to the second surface.

In the embodiment of the application, the upper shell and the lower shell can be respectively held by two mechanical hands, and the two mechanical hands move oppositely until touch and continue to apply force until the ultrasonic welding structure is pressed against the second surface; the lower shell can be fixed at first, then the upper shell is held by a manipulator, and the upper shell is moved to be in contact with the lower shell and then force is continuously applied until the ultrasonic welding structure is pressed against the second surface.

The ultrasonic welding structure is pressed against the second surface, which means that a certain pressure exists between the ultrasonic welding structure and the second surface, and the magnitude of the pressure can be different according to the difference of the surface materials of the upper shell and the lower shell.

And S105, processing the ultrasonic welding structure by using ultrasonic waves, so that the ultrasonic welding structure vibrates in a high frequency mode and generates heat by friction with the second surface.

The specific operation method can convert the current 50/60Hz electric frequency into 20KHz or 40KHz high-frequency electric energy to be supplied to the converter through a transistor functional device, the converter converts the electric energy into mechanical vibration energy for emitting ultrasonic waves, the pressure regulating device transmits the converted mechanical energy to a welding head of the ultrasonic welding machine, the welding head directly transmits the mechanical vibration energy of the ultrasonic waves to the ultrasonic welding structure to cause the ultrasonic welding structure to vibrate at high frequency, and the ultrasonic welding structure vibrates at high frequency to rub with the second surface to generate heat energy.

S106, after the ultrasonic welding structure is heated and melted, removing the ultrasonic wave and continuously pressing the upper shell and the lower shell so that the ultrasonic welding structure forms a first welding surface welded with the first surface and a second welding surface welded with the second surface.

The ultrasonic welding structure is melted by heat generated by friction, after the ultrasonic welding structure is melted, the ultrasonic welding machine is closed, ultrasonic waves are removed, and the ultrasonic welding structure stops vibrating. However, since the temperature of the ultrasonic welding structure is not instantaneously lowered, the ultrasonic welding structure is still in a molten state after the ultrasonic welding structure is removed, and at this time, the pressure is continuously applied to the upper case and the lower case, the ultrasonic welding structure is pressed by the first portion of the lower case, the ultrasonic welding structure is reshaped, and a first welding surface welded to the first surface of the lower case and a second surface welded to the second surface of the lower case are formed. After the ultrasonic welding structure is cooled, the upper case is welded to the lower case.

Referring to fig. 15, fig. 15 is another flowchart of a method for manufacturing a charger according to an embodiment of the present disclosure. Before S104, the method for manufacturing a charger according to the embodiment of the present application further includes:

s1021, forming a through hole in the lower shell;

s1022, assembling the charging element of the charger inside the lower shell and passing the charging wire of the charger through the through hole;

and S1023, electrically connecting the charging wire with the charging element.

In the embodiment of the present application, since the charging element of the charger is disposed in the housing, the charging element needs to be assembled into the housing before the upper shell and the lower shell of the housing are welded. Since the charger itself is not provided with a power supply, the charging element needs to be electrically connected to an external power supply, and therefore, a charging wire needs to be provided. The specific method is that a through hole is arranged on the lower shell, then the charging element is assembled inside the lower shell, then the charging wire penetrates through the through hole from the inside of the lower shell to the outside or from the outside of the lower shell to the inside, and finally one end of the charging wire, which is positioned inside the lower shell, is electrically connected with the charging element. Of course, a through hole may be formed in the lower case, then one end of the charging wire is electrically connected to the charging element, then the charging element connected to the charging wire is assembled inside the lower case, and finally the end of the charging wire, which is not electrically connected to the charging element, passes through the through hole from the inside to the outside of the lower case.

S103, aligning the upper shell and the lower shell so that the ultrasonic welding structure is adjacent to the second surface and a gap is formed between the ultrasonic welding structure and the second part.

In this embodiment, before applying pressure to the upper case and the lower case, the upper case and the lower case need to be aligned, so that the ultrasonic welding structure is adjacent to the second surface and a gap is formed between the ultrasonic welding structure and the second portion, thereby ensuring that the upper case and the lower case after ultrasonic welding are at a preset position. The specific method is that firstly, a preset position of the second surface is marked, the distance between the preset position and the second part is the width of the gap, then the upper shell is moved to the upper part of the lower shell, the edge of the ultrasonic welding structure is aligned with the mark, and finally the upper shell is moved downwards until the ultrasonic welding structure is adjacent to the second surface.

The housing, the charger, and the method for manufacturing the charger according to the embodiments of the present application are described in detail above. The principles and implementations of the present application are described herein using specific examples, which are presented only to aid in understanding the present application. Meanwhile, for those skilled in the art, according to the idea of the present application, there may be variations in the specific embodiments and the application scope, and in summary, the content of the present specification should not be construed as a limitation to the present application.

Claims (11)

1. A housing, comprising:

a lower shell including a first portion having first and second abutting surfaces; and

the upper shell, the upper shell is provided with the ultrasonic bonding structure, the ultrasonic bonding structure can form first face of weld and the second face of weld that adjoins, first face of weld with first surface bonding, the second face of weld with the second surface bonding, so that the upper shell with inferior valve fixed connection.

2. The housing of claim 1, wherein the lower shell further comprises a second portion disposed proud of the second surface.

3. The housing of claim 2, wherein the second portion has a third surface adjacent to the second surface, the upper shell has a fifth surface adjacent to the second bonding surface, and a gap is formed between the fifth surface and the third surface for accommodating a portion of the ultrasonically welded structure that is melted by the ultrasonic bonding.

4. The housing of claim 3, wherein the fifth surface is parallel to the third surface, and the width of the gap is the same in either direction perpendicular to the fifth surface.

5. The housing of claim 3, wherein the second portion further has a fourth surface contiguous with the third surface, the gap tapering from the second surface in a direction toward the fourth surface.

6. A housing according to any one of claims 1 to 5, characterized in that the first surface and/or the second surface is provided with a relief structure for increasing the contact area of the first surface with the first soldering surface and/or the contact area of the second surface with the second soldering surface.

7. A charger, characterized by comprising a housing and a charging member, the charging member being disposed in the housing, the housing being as claimed in any one of claims 1 to 7.

8. The charger according to claim 7, further comprising a charging wire, wherein the lower case is provided with a through hole, the charging wire is arranged in the through hole in a penetrating manner, and the charging element is electrically connected with an external power supply through the charging wire.

9. A method of manufacturing a charger, the method comprising:

providing an upper shell and a lower shell, wherein the lower shell comprises a first part and a second part, the first part is provided with a first surface and a second surface which are adjacent, the second part is arranged in a coplanar manner with one part of the second surface and protrudes out of the second surface, and the upper shell is provided with an ultrasonic welding structure;

pressing the upper case and the lower case to compress the ultrasonic welding structure to the second surface;

ultrasonically treating the ultrasonic welded structure to vibrate the ultrasonic welded structure at a high frequency to frictionally generate heat with the second surface;

and after the ultrasonic welding structure is heated and melted, removing the ultrasonic waves and continuously applying pressure to the upper shell and the lower shell, so that the ultrasonic welding structure forms a first welding surface welded with the first surface and a second welding surface welded with the second surface.

10. The method for manufacturing a charger according to claim 9, further comprising, before said pressing the upper case and the lower case:

aligning the upper shell and the lower shell such that the ultrasonic welding structure is adjacent to the second surface and forms a gap with the second portion.

11. The charger manufacturing method according to claim 10, further comprising, before said aligning said upper case with said lower case:

a through hole is formed in the lower shell;

fitting a charging element of the charger inside the lower case and passing a charging wire of the charger through the through-hole;

electrically connecting the charging wire with the charging element.

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