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The Production System Of The LED Light Sources
LED light bulbs are built around solid-state semiconductor gadgets, so the manufacturing process most closely is similar to that used in making electronic products like PC mother boards.
Let's look into the manufacturing methods for a typical LED light bulb meant to replace a typical incandescent bulb with an Edison Screw. You will find it is a very different process from the highly programmed processes used to produce our familiar incandescent bulbs. And, in spite of what you might think, people are still very much a necessary part of the developing process, and not just for examination and Quality Assurance only.
Once the larger sheets of LED circuit boards have undergone 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 power supply housed in the body of the lamp goes through a similar process, or may be delivered complete from an alternate factory. In either case, the manufacturing procedures 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 add one component at a time. DIP identifies the two parallel rows of leads projecting from the edges of the package. DIP components include all built-in 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 keep the high-power LEDs from overheating. The LED circuit board, which is made up of 1.6-2mm thick aluminum, will carry out the heat from the dozen or so LED elements to the sheet metal 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 coating is electrically insulated. The aluminum PCB is screwed in place within the heatsink which shapes the lower half of the LED light bulb.
Shell assembly consists of shutting 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 permit hot air to escape. Wiring assembly for plug socket needs soldering wires to the bulb socket. Then shell is joined.
Next, the completed 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 failure test and power consumption and energy factor test. Samples from factory run are tested for high-voltage spills, wattage, and power factor (efficiency).
After a final check to guarantee all the different parts of the LED light are tightly held, then it is packed into individual boxes, and bulbs are delivered.
Therefore, if you have wondered why LED light bulbs are so costly today, this information of how they are manufactured and how that compares to the production of traditional light bulbs should help. However, it also reveals why the cost will drop pretty dramatically over the next couple of years. Just as the cost of production other semiconductor-based products has fallen drastically due to standardization, computerization and other key steps along the manufacturing training curve, the same inexorable forces will drive down the prices of LED light bulb production.
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