The Production System Of LED Light Sources

LED light bulbs are built around solid-state semiconductor tools, so the manufacturing process most closely resembles that used to make electronic products like Computer mother boards.

Let's consider the manufacturing steps for a typical LED light bulb meant to replace a common incandescent bulb having an Edison Screw. You can see it is a very different process from the highly automated processes used to manufacture our common incandescent bulbs. And, regardless of what you might imagine, people are still very much a necessary part of the production process, and not for trial and Quality Assurance only.

Once the larger sheets of LED circuit boards have passed through a solder reflow oven (a hot air furnace that melts the solder paste), these are broken up into separate small circuit boards and power wires manually soldered on.

The small power supply housed in the body of the bulb goes through a similar process, or can be delivered complete from the other factory. In either case, the manufacturing steps are the same; first the PCB passes through SMT lines, then it would go to a manual dual in-line package (DIP) setup line where a long row of factory workers add one component at a time. DIP relates to the two parallel rows of wires projecting from every side of the package. DIP components include all integrated chips and chip sockets.

While LED lights burn several times longer than incandescent or CFLs and need less than half the power, they need some form 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 undertake the heat from the dozen or so LED elements to the metal heatsink frame and thus keep temperatures under control. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though made of a conductive material the white coating is electrically coated. The aluminum PCB is actually screwed in place within the heatsink which patterns the lower half of the LED light bulb.

Shell assembly consists of locking the shell in place with screws. A plastic shell covers the power supply and hooks up with the metal heatsink and LED circuit board. Air flow holes are included to allow hot air to escape. Wiring assembly for plug socket needs to have soldering wires to the bulb plug. Then shell is connected.

Next, the completed LED light is sent to burn-in local testing and quality control. The burn-in test usually 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 downfall test and power consumption and power factor test. Samples from the production run are tried for high-voltage leakages, power consumption, and power factor (efficiency).

After a final check with the intention that all the different aspects of the LED light are tighter, then it is packed into individual boxes, and bulbs are shipped.

So, if you have questioned why LED light bulbs are so highly-priced today, this explanation of how they are manufactured and how that compares to the manufacturing of traditional light bulbs should help. However, it also shows why the cost will decrease pretty dramatically over the next few years. Just as the cost of manufacturing other semiconductor-based merchandise has fallen considerably due to standardization, automation and other key steps along the manufacturing education curve, identical inexorable forces will drive down values of LED light bulb production.

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