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The Production System On LED Light Lamps
LED light bulbs are built around solid-state semiconductor devices, so the developing process most closely resembles that used to make electronic products like Desktop mother boards.
Let's consider the manufacturing methods for a typical LED light bulb made to replace a typical incandescent bulb having an Edison Screw. You will see that it is a very distinct process from the highly automated processes used to manufacture our regular incandescent bulbs. And, regardless of what you might think, people are still very much a significant part of the developing process, and not for testing and Quality Assurance only.
Once the bigger sheets of LED circuit boards have passed through a solder reflow oven (a hot air furnace that melts the solder paste), the sheets are broken up into separate small circuit boards and power cables manually soldered on.
The small power source housed in the body of the lamp goes through a similar process, or can be delivered complete from another factory. Either way, the manufacturing steps are the same; first the PCB passes through SMT lines, then it is sent to a manual dual in-line package (DIP) setup line where a long row of factory employees attach one component at a time. DIP identifies the two parallel rows of wires projecting from the sides of the package. DIP elements include all integrated chips and chip sockets.
While LED lights burn several times longer than incandescent or CFLs and demand less than half the power, they need some type of passive heatsink to sustain the high-power LEDs from overheating. The LED circuit board, which is made up of 1.6-2mm thick light weight aluminum, will conduct the heat from the dozen or so LED materials to the metal heatsink frame and 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 insulated. The aluminum PCB is actually screwed in place within the heatsink which forms the lower half of the LED light bulb.
Shell setup consists of locking 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 device for plug socket needs soldering wires to the bulb plug. Then shell is attached.
Next, the finished LED light is sent to burn-in tests and quality control. The burn-in test usually lasts for 30 minutes. The final LED light bulb is then operated up to see if it is working appropriately and burned in for 30 minutes. There is also a high-voltage discharging and breakdown test and wattage and power factor test. Samples from the production run are verified for high-voltage leakages, wattage, and electricity factor (efficiency).
After a final check to guarantee all the different aspects of the LED light are tight, then it is fitted within individual boxes, and bulbs are shipped.
So, if you have questioned why LED light bulbs are so highly-priced today, this information of how they are created and how that compares to the production of traditional light bulbs should help. However, it also shows why the cost will fall pretty significantly over the next few years. Just as the cost of manufacturing other semiconductor-based goods has fallen considerably due to standardization, computerization and other key procedures along the manufacturing training curve, identical inexorable forces will drive down the costs of LED light bulb production.
The Production System On LED Light Lamps
LED light bulbs are built around solid-state semiconductor devices, so the manufacturing process most closely resembles that used to make electronic products like PC mother boards.
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