Let's check out the production steps for a typical LED light bulb intended to change a regular incandescent bulb with an Edison Screw. You will see that it is a very distinct process from the highly automatic procedures used to produce our familiar incandescent bulbs. And also, regardless of what you might imagine, individuals are still quite an essential part of manufacturing method, and not simply for testing and also Quality Assurance either.

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Once the bigger sheets of LED circuit boards have passed through a solder reflow micro wave (a hot air furnace that melts the solder mixture), they are broken up into the different compact circuit boards and also power wires manually soldered on.

The small power supply housed in the body of the light bulb goes through a similar process, or perhaps might be delivered complete from a different factory. Either way, the producing steps are the exact same; first the PCB passes through SMT lines, then it goes to a manual dual in-line package (DIP) set up line in which a really long row of factory workers add one component at one point. DIP refers to the two parallel rows of leads starting from the sides of the package. DIP elements include all integrated chips and also chip sockets.

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When LED lights burn many times longer compared to incandescent or maybe CFLs and also require less than half the energy, they need some sort of passive heatsink always keep the high-power LEDs from overheating. The LED circuit board, that is made from 1.6-2mm thick aluminum, will certainly conduct the heat from the dozen or more LED elements to the metal heatsink frame therefore keep temperatures in check. Aluminum-backed PCBs are sometimes called "metal core printed circuit boards," and also although made from a conductive material the white coating is electrically isolating. The aluminum PCB is screwed in position within the heatsink which makes the lower half of the LED bulb.

After this, the power connector board is fixed in place with adhesive. The small power supply transforms 120/240V AC mains power to a lower voltage (12V or perhaps 24V), it will fit in the cavity behind the aluminum PCB.

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Next, the accomplished LED light is delivered to burn-in testing and also quality control. The burn-in test typically lasts for 30 minutes. The done LED light bulb is then operated up to check if it is working properly and burned in for half an hour. Additionally there is a high-voltage leakage and also breakdown test and power consumption and power factor check. Product samples from the production run are examined for high-voltage leaks, power consumption, and power issue (performance).

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The completed bulbs pass through one final crimping step as the metal socket base is crimped in place, are bar-coded and also identified with lot numbers. External safety tags are applied and the light bulb is inked with information, just like brand together with design number. Finally, all that's left is to fix on the clear plastic LED cover that is fixed in place.

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After the final check to make sure all of the different parts of the LED light are tight, then it is packed into different boxes, and also bulbs are shipped out.

So, in case you have wondered why LED light bulbs are so costly nowadays, this explanation of how they are made as well as how that compares to the production of traditional light bulbs should help. However, it also reveals the reason why the price will decrease pretty greatly over the upcoming couple of years.

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Installing LED tube lights is an excellent means to save money on electricity and get potentially unhealthy fluorescent lights out of your house or office. But, most LED light tubes available nowadays can not be directly installed.

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