The Growth Technology On Led Light Sources

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 take a look at the manufacturing methods for a typical LED light bulb designed to replace a common incandescent bulb having an Edison Screw. You will find it is a very different process from the highly automated processes used to produce our familiar incandescent bulbs. And, despite what you might imagine, people are still very much a necessary part of manufacturing process, and not for testing and Quality Assurance only.

Once the bigger sheets of LED circuit boards have undergone a solder reflow oven (a hot air kiln that melts the solder paste), they are broken up into separate small circuit boards and power wires manually soldered on.

The small power source housed in the body of the light bulb goes through a similar process, or may be delivered complete from another factory. In any event, the manufacturing phases are the same; first the PCB passes through SMT lines, then it would go to a manual dual in-line package (DIP) installation line where a long row of factory workers attach one component at a time. DIP relates to the two parallel rows of links projecting from the edges of the package. DIP substances include all integral 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 prepared from 1.6-2mm thick metal, will undertake the heat from the dozen or so LED materials to the metal heatsink frame thus keep temperatures well in hand. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though made from a conductive material the white outside layer is electrically coated. The aluminum PCB is actually 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 attaches with the metal heatsink and LED circuit board. Air flow holes are included to permit hot air to escape. Wiring setup for plug socket needs soldering wires to the bulb attachment. Then shell is connected.

Next, the finished LED , enters burn-in tests and quality control. The burn-in test usually lasts for 30 minutes. The completed LED light bulb is then powered up to see if it is working correctly and burned in for 30 minutes. There is also a high-voltage discharging and downfall test and power consumption and energy factor test. Samples from producer run are tried for high-voltage spills, wattage, and electricity factor (efficiency).

After a final check to guarantee all the different components of the LED light are tight, then it is fitted within individual boxes, and bulbs are shipped.

So, if you have wondered why LED light bulbs are so highly-priced today, this justification of how they are created and how that compares to the production of traditional light bulbs should help. However, it also reveals why the cost will fall pretty dramatically over the next couple of years. Just as the cost of manufacturing other semiconductor-based merchandise has fallen drastically due to standardization, mechanization and other key measures along the manufacturing learning curve, identical inexorable forces will drive down values of LED light bulb production.

by: John Reid

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