LED light bulbs are built around solid-state semiconductor gadgets, so the production process most closely resembles that applied in making electronic products like PC mother boards.
Let's consider the manufacturing methods for a typical LED light bulb meant to replace a standard incandescent bulb having an Edison Screw. You will find it is a very unique process from the highly automated processes used to assemble our familiar incandescent bulbs. And, regardless of what you might think, people are still very much a necessary part of manufacturing process, and not for examination and Quality Assurance only.
Once the more sheets of LED circuit boards have passed through a solder reflow oven (a hot air kiln that melts the solder paste), they are broken up into separate small circuit boards and power cables 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 an alternate factory. In any event, the manufacturing steps are the same; first the PCB transmits through SMT lines, then it goes to a manual dual in-line package (DIP) setup line where a long row of factory employees add one component at a time. DIP refers to the two parallel rows of wires projecting from the edges of the package. DIP substances include all integrated chips and chip sockets.
While LED lights burn couple of times longer than incandescent or CFLs and require less than half the power, they need some type 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 carry out the heat from the dozen or so LED components to the metal heatsink frame thus keep temperatures in check. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though made from a conductive material the white coating is electrically isolating. The aluminum PCB is actually screwed in place within the heatsink which shapes the lower half of the LED light bulb.
Shell setting up consists of locking the shell in place with screws. A plastic shell hides the power supply and connects with the metal heatsink and LED circuit board. Air flow holes are included to permit hot air to escape. Wiring assembly for plug socket requires soldering wires to the bulb plug. Then shell is joined.
Next, the final product LED light enters burn-in testing and quality control. The burn-in test usually lasts for 30 minutes. The final 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 failure test and wattage and power factor test. Samples from producer run are tested for high-voltage leakages, wattage, and power factor (efficiency).
After a final check to make sure all the different aspects of the LED light are tightly held, then it is arranged into individual boxes, and bulbs are shipped.
Thus, if you have wondered why LED light bulbs are so highly-priced today, this information 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 drop pretty drastically over the next few years. Just as the cost of developing other semiconductor-based products has fallen considerably due to standardization, computerization and other key steps along the manufacturing learning curve, identical inexorable forces will drive down the prices of LED light bulb production.
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Let's consider the manufacturing methods for a typical LED light bulb meant to replace a standard incandescent bulb having an Edison Screw. You will find it is a very unique process from the highly automated processes used to assemble our familiar incandescent bulbs. And, regardless of what you might think, people are still very much a necessary part of manufacturing process, and not for examination and Quality Assurance only.
Once the more sheets of LED circuit boards have passed through a solder reflow oven (a hot air kiln that melts the solder paste), they are broken up into separate small circuit boards and power cables 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 an alternate factory. In any event, the manufacturing steps are the same; first the PCB transmits through SMT lines, then it goes to a manual dual in-line package (DIP) setup line where a long row of factory employees add one component at a time. DIP refers to the two parallel rows of wires projecting from the edges of the package. DIP substances include all integrated chips and chip sockets.
While LED lights burn couple of times longer than incandescent or CFLs and require less than half the power, they need some type 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 carry out the heat from the dozen or so LED components to the metal heatsink frame thus keep temperatures in check. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though made from a conductive material the white coating is electrically isolating. The aluminum PCB is actually screwed in place within the heatsink which shapes the lower half of the LED light bulb.
Shell setting up consists of locking the shell in place with screws. A plastic shell hides the power supply and connects with the metal heatsink and LED circuit board. Air flow holes are included to permit hot air to escape. Wiring assembly for plug socket requires soldering wires to the bulb plug. Then shell is joined.
Next, the final product LED light enters burn-in testing and quality control. The burn-in test usually lasts for 30 minutes. The final 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 failure test and wattage and power factor test. Samples from producer run are tested for high-voltage leakages, wattage, and power factor (efficiency).
After a final check to make sure all the different aspects of the LED light are tightly held, then it is arranged into individual boxes, and bulbs are shipped.
Thus, if you have wondered why LED light bulbs are so highly-priced today, this information 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 drop pretty drastically over the next few years. Just as the cost of developing other semiconductor-based products has fallen considerably due to standardization, computerization and other key steps along the manufacturing learning curve, identical inexorable forces will drive down the prices of LED light bulb production.
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