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 China Prototype PCB. 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 PCB Prototype Manufacturer.
The
small supply of power housed in the body of the bulb goes through a similar
process, or 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 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.
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