Eating Healthy for Life

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 PC mother boards.

Let's look into the manufacturing methods for a typical LED light bulb designed to replace a typical incandescent bulb with an Edison Screw. You will see that it is a very distinct process from the highly computerized processes used to produce our familiar incandescent bulbs. And, in spite of what you might think, people are still very much an important part of the developing process, and not just 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), they are broken up into single small circuit boards and power cables manually soldered on.

The small supply of power housed in the body of the lamp goes through a similar process, or may be delivered complete from another factory. Either way, the manufacturing phases are the same; first the PCB sends through SMT lines, then it goes to a manual dual in-line package (DIP) installation line where a long row of factory employees put in one component at a time. DIP identifies the two parallel rows of leads 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 require less than half the electricity, they need some type of passive heatsink to keep the high-power LEDs from overheating. The LED circuit board, which is made up of 1.6-2mm thick aluminum, will conduct the heat from the dozen or so LED materials to the metallic heatsink frame and therefore keep temperatures in check. Aluminum-backed PCBs are frequently called "metal core printed circuit boards," and though made from a conductive material the white covering is electrically insulated. The aluminum PCB is 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 connects with the metal heatsink and LED circuit board. Venting holes are included to allow hot air to escape. Wiring setup for plug socket needs soldering wires to the bulb socket. Then shell is attached.

Next, the finished LED , goes to burn-in testing and quality control. The burn-in test generally lasts for 30 minutes. The final LED light bulb is then powered up to see if it is working appropriately and burned in for 30 minutes. There is also a high-voltage leakage and breakdown test and power consumption and energy factor test. Samples from factory run are tested for high-voltage spills, wattage, and energy factor (efficiency).

After a final check to guarantee all the different parts of the LED light are tight, then it is fitted within individual boxes, and bulbs are transported.

Therefore, if you have wondered why LED light bulbs are so costly today, this information of how they are produced and how that compares to the production 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 production other semiconductor-based products has fallen drastically due to standardization, computerization and other key measures along the manufacturing training curve, the same inexorable forces will drive down the costs of LED light bulb production.

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