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The Production Process Of The LED Light Sources

LED light bulbs are built around solid-state semiconductor devices, so the developing process most closely is identical to that used in making electronic products like Desktop mother boards.

Let's look into the manufacturing steps for a typical LED light bulb designed to replace a common incandescent bulb having an Edison Screw. You will see that it is a very distinct process from the highly computerized processes used to produce our regular incandescent bulbs. And, in spite of what you might imagine, people are still very much an important part of the production process, and not for testing and Quality Assurance only.

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

The small supply of power housed in the body of the bulb goes through a similar process, or can be delivered complete from another factory. Either way, the manufacturing phases 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 workers put in one component at a time. DIP relates to the two parallel rows of wires projecting from the sides of the package. DIP elements include all integral chips and chip sockets.

While LED lights burn in many cases longer than incandescent or CFLs and demand less than half the electricity, they need some form of passive heatsink to 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 materials to the metallic heatsink frame and therefore keep temperatures well in hand. Aluminum-backed PCBs are frequently called "metal core printed circuit boards," and though made of a conductive material the white covering is electrically coated. 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 safety locking the shell in place with screws. A plastic shell shelters the power supply and attaches with the metal heatsink and LED circuit board. Venting holes are included to allow hot air to escape. Wiring setup for plug socket needs to have soldering wires to the bulb plug. Then shell is attached.

Next, the finished LED , goes to burn-in tests and quality control. The burn-in test generally 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 breakdown test and wattage and energy factor test. Samples from factory run are verified for high-voltage spills, power consumption, and energy factor (efficiency).

After a final check with the intention that all the different aspects of the LED light are tight, then it is fitted within individual boxes, and bulbs are transported.

Therefore, if you have questioned why LED light bulbs are so costly today, this explanation of how they are produced and how that compares to the manufacturing of traditional light bulbs should help. However, it also shows why the cost will fall pretty significantly over the next several years. Just as the cost of production other semiconductor-based goods has fallen drastically due to standardization, automation and other key measures along the manufacturing education curve, identical inexorable forces will drive down the costs of LED light bulb production.

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