The Production System Of Led Light Sources

LED light bulbs~ are built around solid-state semiconductor tools

, so the production process most closely resembles that used in making electronic products like Desktop mother boards.

Let's consider the manufacturing steps for a typical LED light bulb made to replace a standard incandescent bulb with an Edison Screw. You can see it is a very unique process from the highly automated processes used to assemble our common incandescent bulbs. And, despite what you might think, people are still very much a significant part of the production process, and not for trial and Quality Assurance only.

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

The small supply of power housed in the body of the light bulb goes through a similar process, or may be delivered complete from an alternate factory. In any event, the manufacturing steps are the same; first the PCB sends through SMT lines, then it is sent to a manual dual in-line package (DIP) installation line where a long row of factory workforce add one component at a time. DIP refers to the two parallel rows of leads projecting from every side of the package. DIP elements include all integrated chips and chip sockets.

While LED lights burn several times longer than incandescent or CFLs and need less than half the electricity, they need some kind of passive heatsink keep the high-power LEDs from overheating. The LED circuit board, which is prepared from 1.6-2mm thick light weight aluminum, will conduct the heat from the dozen or so LED elements to the metallic heatsink frame thus keep temperatures in check. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though made of a conductive material the white covering 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 assembly consists of shutting the shell in place with screws. A plastic shell shelters the power supply and hooks up with the metal heatsink and LED circuit board. Ventilation holes are included to permit hot air to escape. Wiring setup for plug socket needs soldering wires to the bulb attachment. Then shell is joined.

Next, the completed LED light goes to burn-in local 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 seepage and downfall test and wattage and power factor test. Samples from the production run are verified for high-voltage spills, power consumption, and power factor (efficiency).

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

Thus, if you have wondered why LED light bulbs are so costly today, this information 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 decrease pretty dramatically over the next several years. Just as the cost of developing other semiconductor-based products has fallen drastically due to standardization, mechanization and other key procedures along the manufacturing training curve, similar inexorable forces will drive down the prices of LED light bulb production.

by: John Reid

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