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The Advancement Process Of The LED Light Bulbs
LED light bulbs are built around solid-state semiconductor tools, so the production process most closely is identical to that used to make electronic products like Desktop mother boards.
Let's take a look at the manufacturing ways for a typical LED light bulb meant to replace a standard incandescent bulb having an Edison Screw. You can see it is a very unique process from the highly computerized processes used to manufacture our regular incandescent bulbs. And, despite what you might believe, people are still very much a necessary part of manufacturing process, and not for trial and Quality Assurance only.
Once the more sheets of LED circuit boards have gone through a solder reflow oven (a hot air furnace that melts the solder paste), the sheets are broken up into the individual small circuit boards and power leads manually soldered on.
The small power supply housed in the body of the light bulb goes through a similar process, or can be delivered complete from the other factory. In any event, the manufacturing phases are the same; first the PCB passes through SMT lines, then it is sent to a manual dual in-line package (DIP) assembly line where a long row of factory workforce add one component at a time. DIP refers to the two parallel rows of wires projecting from every side of the package. DIP substances include all integral chips and chip sockets.
While LED lights burn several times longer than incandescent or CFLs and demand less than half the energy, they need some kind of passive heatsink keep the high-power LEDs from overheating. The LED circuit board, which is made from 1.6-2mm thick light weight aluminum, will undertake the heat from the dozen or so LED components to the metallic heatsink frame and thus keep temperatures well in hand. Aluminum-backed PCBs are sometimes called "metal core printed circuit boards," and though manufactured from a conductive material the white coating is electrically isolating. The aluminum PCB is actually screwed in place within the heatsink which patterns the lower half of the LED light bulb.
Shell setting up consists of safety locking the shell in place with screws. A plastic shell covers the power supply and attaches with the metal heatsink and LED circuit board. Ventilation holes are included to permit hot air to escape. Wiring assembly for plug socket requires soldering wires to the bulb plug. Then shell is connected.
Next, the final product LED , is sent to burn-in tests and quality control. The burn-in test typically lasts for 30 minutes. The finished product, LED light bulb is then powered up to see if it is working properly and burned in for 30 minutes. There is also a high-voltage discharging and downfall test and wattage and energy factor test. Samples from the production run are verified for high-voltage leaks, energy used, and power factor (efficiency).
After a final check to make sure all the different aspects of the LED light are tighter, then it is arranged into individual boxes, and bulbs are transported.
So, if you have questioned why LED light bulbs are so expensive today, this justification of how they are manufactured and how that compares to the manufacture of traditional light bulbs should help. However, it also shows why the cost will decrease pretty drastically over the next several years. Just as the cost of manufacturing other semiconductor-based goods has fallen dramatically due to standardization, mechanization and other key steps along the manufacturing learning curve, identical inexorable forces will drive down values of LED light bulb production.
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