Vehicle Dash Light Bulbs – One-hundred-and-thirty ages ago, Thomas Edison completed the first successful sustained test of the incandescent light bulb. With some incremental improvements along the way, Edison’s basic technology has lit the world ever since. This is all about to change. We are on the cusp of a semiconductor-based lighting revolution which will ultimately replace Edison’s bulbs using a far more energy-efficient lighting alternative. Solid state LED lighting will gradually replace almost all of the countless billions of fluorescent and incandescent lights being used around the world these days. In fact, as a step along this path, President Obama last June unveiled new, stricter lighting criteria that will encourage the phasing out of incandescent bulbs (which are prohibited in parts of Europe).
To understand just how revolutionary LED light bulbs are as well as why they are still expensive, it’s instructive to look at how they are fabricated and to compare this to the manufacture of incandescent light bulbs. This article investigates how incandescent light bulbs are created and then contrasts that process with a description of the typical manufacturing process for LED light bulbs. So, let us start by taking a look at just how conventional incandescent light bulbs are manufactured. You’ll find this really is a classic instance of an automatic industrial process elegant in more than a century of experience.
While human incandescent light bulb forms vary in size and wattage, so all of them have the three basic components: the filament, the bulb, and the base. The filament is made of tungsten. While very fragile, tungsten filaments can withstand temperatures of 4,500 degrees Fahrenheit and above. The connecting or lead-in wires are typically made of nickel-iron wire. This wire is dipped to a borax way to make the wire more adherent to glass. The bulb itself is made of glass and contains a combination of gases, generally argon and nitrogen, which increase the life of the filament. Air is pumped from the bulb and replaced using all the gases. A standardized base holds the whole assembly in place. Aluminum is used on the exterior and glass used to insulate the interior of the base.
Originally produced by hand, light bulb manufacturing is currently almost entirely automated. |} To begin with, the filament is fabricated with a process known as drawing, where tungsten is mixed with a binder material and pulled through a die (a shaped orifice) to a nice wire. Next, the wire is wrapped around a metal bar called a mandrel so as to mold it to its proper coiled shape, and then it’s heated in a process known as annealing, softening the wire and leaves its construction more uniform. The mandrel is then dissolved in acid. Secondly, the coiled filament is connected to the lead-in wires. The lead-in wires have pins at their ends which are either pressed on the conclusion of the filament or, in larger bulbs, spot-welded.
Third, the glass bulbs or casings are made using a ribbon system. Once heating in a furnace, a continuous ribbon of glass goes along a conveyor belt. Precisely aligned air nozzles blow off the glass through holes at the conveyor belt to molds, making the casings. A ribbon machine moving at top speed can produce more than 50,000 bulbs each hour. Following the casings are dismissed, they are chilled and then cut off from the ribbon system. Next, the interior of the bulb is coated with silica to eliminate the glare caused by a luminous, uncovered filament. The label and wattage are then stamped onto the exterior top of each shell.