The Manufacturing System On LED Light Lamps

LED light bulbs are built around solid-state semiconductor devices, so the production process most closely resembles that applied in making electronic products like PC mother boards.

Let's take a look at the manufacturing ways for a typical LED light bulb made to replace a standard incandescent bulb using an Edison Screw. You will see that it is a very unique process from the highly automated processes used to assemble our familiar incandescent bulbs. And, despite what you might believe, people are still very much a significant part of manufacturing process, instead of just for testing 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 the individual small circuit boards and power leads manually soldered on.

The small power source housed in the body of the light bulb goes through a similar process, or could be delivered complete from another 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) assembly line where a long row of factory workforce attach one component at a time. DIP refers to the two parallel rows of links projecting from the sides 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 energy, they need some kind of passive heatsink to sustain the high-power LEDs from overheating. The LED circuit board, which is made from 1.6-2mm thick metal, will conduct the heat from the dozen or so LED components to the metal heatsink frame thus keep temperatures in check. Aluminum-backed PCBs are sometimes called "metal core printed circuit boards," and though manufactured from a conductive material the white outside layer is electrically isolating. The aluminum PCB is usually screwed in place within the heatsink which forms 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. Ventilation holes are included to permit hot air to escape. Wiring device for plug socket requires soldering wires to the bulb attachment. Then shell is attached.

Next, the final product LED light enters burn-in testing and quality control. The burn-in test typically lasts for 30 minutes. The finished product, LED light bulb is then operated up to see if it is working properly and burned in for 30 minutes. There is also a high-voltage seepage and breakdown test and wattage and power factor test. Samples from producer run are tested for high-voltage leaks, energy used, and electricity factor (efficiency).

After a final check to make sure all the different components of the LED light are tight, then it is arranged into individual boxes, and bulbs are shipped.

Thus, if you have wondered why LED light bulbs are so expensive today, this justification of how they are created and how that compares to the manufacture of traditional light bulbs should help. However, it also compares why the cost will fall pretty drastically over the next few years. Just as the cost of developing other semiconductor-based products has fallen dramatically due to standardization, mechanization and other key procedures along the manufacturing learning curve, similar inexorable forces will drive down the costs of LED light bulb production.

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The Manufacturing System On LED Light Lamps

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