The Production System On LED Light Sources
LED light bulbs are built around solid-state semiconductor gadgets, so the manufacturing process most closely is identical to that applied in making electronic products like PC mother boards.
Let's consider the manufacturing ways for a typical LED light bulb made to replace a typical incandescent bulb with an Edison Screw. You will find it is a very different process from the highly computerized processes used to assemble our familiar incandescent bulbs. And, regardless of what you might believe, people are still very much a significant part of the developing process, and not just for examination and Quality Assurance only.
Once the larger sheets of LED circuit boards have gone through a solder reflow oven (a hot air kiln that melts the solder paste), they are broken up into separate small circuit boards and power leads manually soldered on.
The small power source 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 phases are the same; first the PCB transmits through SMT lines, then it goes to a manual dual in-line package (DIP) setup line where a long row of factory workforce attach one component at a time. DIP identifies the two parallel rows of leads projecting from the edges of the package. DIP components include all integral chips and chip sockets.
While LED lights burn couple of times longer than incandescent or CFLs and require less than half the power, they need some kind of passive heatsink to sustain 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 metallic heatsink frame thus keep temperatures in check. Aluminum-backed PCBs are usually called "metal core printed circuit boards," and though manufactured from a conductive material the white outside layer 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 safety locking the shell in place with screws. A plastic shell hides the power supply and connects with the metal heatsink and LED circuit board. Air flow holes are included to permit hot air to escape. Wiring device for plug socket needs soldering wires to the bulb socket. Then shell is joined.
Next, the completed LED , enters burn-in testing and quality control. The burn-in test usually lasts for 30 minutes. The finished product, LED light bulb is then operated 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 producer run are tested for high-voltage leakages, energy used, and electricity 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 transported.
Thus, if you have wondered why LED light bulbs are so highly-priced today, this justification of how they are created 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 several years. Just as the cost of developing other semiconductor-based products has fallen considerably due to standardization, mechanization and other key procedures along the manufacturing training curve, the same inexorable forces will drive down the prices of LED light bulb production.
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