The Manufacturing System Of LED Light Bulbs LED light bulbs~ are built around solid-state semiconductor gadgets, so the manufacturing process most closely resembles that used to make electronic products like PC mother boards.
Let's take a look at the manufacturing ways for a typical LED light bulb meant to replace a typical incandescent bulb with an Edison Screw. You can see it is a very distinct process from the highly automated processes used to produce our regular incandescent bulbs. And, in spite of what you might think, people are still very much an important part of manufacturing process, and not just for examination and Quality Assurance only.
Once the bigger sheets of LED circuit boards have undergone a solder reflow oven (a hot air heater that melts the solder paste), these are broken up into separate small circuit boards and power leads manually soldered on.
The small supply of power housed in the body of the bulb goes through a similar process, or http://pcbonline.lofter.com/ can be delivered complete from the other factory. Either way, the manufacturing procedures 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 attach one component at a time. DIP relates to the two parallel rows of wires projecting from the sides of the package. DIP components include all built-in chips and chip sockets.
While LED lights burn several times longer than incandescent or CFLs and demand less than half the electricity, they need some kind of passive heatsink to sustain the high-power LEDs from overheating. The LED circuit board, which is made up of 1.6-2mm thick metal, will carry out the heat http://www.bloghotel.org/pcbonline/ from the dozen or so LED materials to the metallic heatsink frame and thus keep temperatures well in hand. Aluminum-backed PCBs are frequently called "metal core printed circuit boards," and though manufactured from a conductive material the white coating is electrically isolating. The aluminum PCB is usually screwed in place within the heatsink which shapes the lower half of the LED light bulb.
Shell assembly consists of shutting the shell in place with screws. A plastic shell covers the power supply and connects with the metal heatsink and LED circuit board. Ventilation holes are included to permit hot air to escape. Wiring assembly for plug socket needs soldering wires to the bulb attachment. Then shell is connected.
Next, the completed LED , is sent to burn-in local testing and quality control. The burn-in test typically lasts for 30 minutes. The final LED light bulb is then operated up to see if it is working correctly 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 spills, wattage, and energy factor (efficiency).
After a final check to make sure all the different components of the LED light are tighter, then it is arranged into individual boxes, and bulbs are delivered.
Therefore, if you have questioned why LED light bulbs are so costly today, this information of how they are created and how that compares to the manufacturing of traditional light bulbs should help. However, it also reveals why the cost will fall pretty significantly over the next several years. Just as the cost of manufacturing other semiconductor-based merchandise has fallen drastically due to standardization, mechanization and other key steps along the manufacturing learning curve, identical inexorable forces will drive down the costs of LED light bulb production.