Let's check out the manufacturing steps for a typical LED light bulb designed to change a standard incandescent bulb with an Edison Screw. You will discover that it really is a very distinct process from the highly automatic processes used to manufacture our familiar incandescent bulbs. And also, despite everything you may imagine, individuals are still quite a necessary part of manufacturing process, and not simply for testing and High quality Guarantee either.
Allow me to share 4 convincing reasons why you need to buy LED light bulbs very soon. All these reasons take into accout previous misconceptions on LEDs and will assist you to see and realize better its advantages..
Once the bigger sheets of LED circuit boards have passed through a solder reflow micro wave (a hot air furnace that melts the solder paste), they are broken up into the individual compact circuit boards and power wires manually soldered on.
The small supply of power housed in the body of the light bulb goes through an identical process, or perhaps might be delivered complete from another factory. In either case, the producing steps are the same; at first the PCB passes through SMT lines, after which it goes to a manual dual in-line package (DIP) set up line in which a long row of factory workers add one component at a time. DIP refers to the two parallel rows of leads starting from the sides of the package. DIP components consist of all of the integrated chips and also chip sockets.
When LED lights burn several times longer than incandescent or maybe CFLs and require least compared to half the energy, they need some sort of passive heatsink always keep the high-power LEDs from overheating. The LED circuit board, which is made from 1.6-2mm thick aluminum, will conduct the heat from the dozen or more LED elements to the metal heatsink frame and thus keep temperatures under control. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and also although made of a conductive material the white coating is electrically isolating. The aluminum PCB is screwed in place within the heatsink which makes the lower half of the LED light bulb.
After this, the electrical power connector board is mounted in place with adhesive. The small power supply transforms 120/240V AC mains power to a lower voltage (12V or perhaps 24V), it fits in the cavity behind the aluminum PCB.
Next, the finished LED light is delivered to burn-in testing and quality control. The burn-in test normally can last for 30 minutes. The done LED light bulb is then operated up to see if it is working properly and burned in for 30 minutes. Additionally there is a high-voltage leakage and breakdown test together with power usage and power factor check. Product samples from the production run are tested for high-voltage leaks, power consumption, and power factor (performance).
The finished bulbs go through one last crimping step as the metal socket base is crimped in place, are bar-coded and also identified with lot numbers. External safety tags are applied and the bulb is inked with data, such as brand together with model number. At last, almost all that's left is to fix on the clear plastic LED cover that is fixed in place.
After a final check to make sure all the various parts of the LED light are tight, then it is packed into different boxes, and bulbs are delivered away.
So, in case you have wondered why LED light bulbs are so costly today, this explanation of how they are produced as well as how that compares to the manufacture of traditional light bulbs can certainly help. However, this also reveals the reason why the price will fall pretty significantly over the upcoming few years.
DIP Refers To The Two Parallel Rows Of Leads Starting From The Sides Of The Package
Let's check out the manufacturing steps for a typical LED light bulb intended to replace a common incandescent bulb with an Edison Screw.
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