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Let's take a look at the production steps for a regular LED light bulb meant to change a standard incandescent bulb with an Edison Screw. You will see that it is an extremely distinct process from the highly automated procedures utilized to manufacture our familiar incandescent bulbs. And also, despite what you might think about, individuals are still very much an essential part of producing process, and not simply for testing and Quality Assurance either.

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As soon as the bigger sheets of LED circuit boards have passed through a solder reflow oven (a hot air furnace that melts the solder mixture), they may be broken up into the individual compact circuit boards and power wires manually soldered on.

The small power supply housed in the body of the light bulb goes through a similar procedure, or perhaps may be delivered complete from a different manufacturing plant. In either case, the producing steps are the same; first the PCB passes through SMT lines, then it is sent to a manual dual in-line package (DIP) set up line where a really long row of factory employees add one component at a time. DIP refers to the two parallel rows of leads starting from the sides of the package. DIP components include all incorporated chips and also chip sockets.

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While LED lights burn many times much more time than incandescent or maybe CFLs and require less than half the energy, they require some type of passive heatsink keep the high-power LEDs from overheating. The LED circuit board, that is made out of 1.6-2mm thick aluminum, will conduct the heat from the dozen or more LED elements to the metal heatsink frame and thus keep temperatures in check. Aluminum-backed PCBs are sometimes known as "metal core printed circuit boards," and also though made from a conductive material the white coating is electrically coated. The aluminum PCB is screwed in place within the heatsink which makes the lower half of the LED light bulb.

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

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Following that, the completed LED light is delivered to burn-in testing and quality control. The burn-in test typically lasts for half an hour. The finished LED light bulb is then powered up to check if it is working effectively and burned in for 30 minutes. Additionally there is a high-voltage leakage and breakdown test and power consumption as well as power factor check. Samples from the production run are examined for high-voltage leaks, power consumption, and also power factor (performance).

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The finished bulbs pass through one final crimping step since the metal socket base is crimped in place, are bar-coded and also identified with lot numbers. External safety labels are applied and the light bulb is inked with details, such as brand together with model number. Finally, all that's left is to fix on the thoroughly clean plastic LED cover that is glued in place.

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

Therefore, in case you have wondered why LED light bulbs are so expensive nowadays, this justification of how they are manufactured as well as how that compares to the manufacture of traditional light bulbs should help. However, it also discloses exactly why the cost will decrease quiet dramatically over the upcoming few years.

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