Energy Smart Light Bulb Conversion

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Energy Smart Light Bulb Conversion – One-hundred-and-thirty years back, Thomas Edison completed the first successful ongoing evaluation of the incandescent light bulb. With a few incremental improvements along the way, Edison’s fundamental technology has lit the world ever since. This is about to change. We are on the cusp of a semiconductor-based lighting revolution which will finally replace Edison’s bulbs with a far more energy-efficient lighting alternative. Solid state LED lighting will eventually replace virtually every one the hundreds of billions of incandescent and fluorescent lights in use around the world today.

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To know just how revolutionary LED light bulbs are and why they’re still expensive, it is instructive to check at how they’re fabricated and also to compare this to the manufacture of incandescent bulbs. This article explores how incandescent light bulbs are made then contrasts that process with a description of the normal production process for LED light bulbs. So, let’s begin by having a look at how traditional incandescent light bulbs are manufactured. You’ll find that this really is a classic instance of an automatic industrial process refined in more than a century of expertise.


While individual incandescent light bulb types vary in size and wattage, so all of them have the three primary parts: the filament, the bulb, and also the foundation. The filament is made of tungsten. While very brittle, tungsten filaments can withstand temperatures of 4,500 degrees Fahrenheit and above. The linking or lead-in cables 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 with the gases. A standardized foundation holds the whole assembly in place. The foundation is known as the ” Edison screw base.” Aluminum is used on the exterior and glass used to insulate the inside of the base.

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Originally produced by hand, light bulb manufacturing is currently almost entirely automated. |} First, the filament is fabricated using a process known as drawing, in which tungsten is mixed with a binder cloth and pulled through a die (a shaped orifice) to a nice wire. Next, the wire is wound around a metal bar called a mandrel in order to mold it to its appropriate coiled shape, after that it is heated in a process known as annealing, softening the wire and makes its structure more uniform. Second, the coiled filament is attached to the lead-in cables. The lead-in cables have hooks at their ends which are either pressed over the conclusion of the filament or, in bigger bulbs, spot-welded.

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Third, the glass lamps or casings are produced using a ribbon machine. After heating in a furnace, then a continuous ribbon of glass goes along a conveyor belt. Precisely aligned air nozzles blow the glass holes at the conveyor belt to molds, making the casings. A ribbon machine moving at top speed can create greater than 50,000 bulbs each hour. Following the casings are dismissed, they are chilled and then cut from the ribbon machine. Next, the inside of the bulb is coated with silica to eliminate the glare brought on by a glowing, discovered filament. The label and wattage are then stamped on the exterior top of every casing.