Static Electricity Experiments Balloon Light Bulb – One-hundred-and-thirty ages ago, Thomas Edison completed the first successful ongoing test of the incandescent light bulb. With a few incremental improvements on the way, Edison’s basic technology has lit the world ever since. This is about to change. We’re on the cusp of a semiconductor-based lighting revolution which will finally replace Edison’s bulbs using a far more energy-efficient lighting solution. Solid state LED lighting will gradually replace virtually all 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 introduced new, more rigorous lighting criteria that will support the phasing out of incandescent bulbs (which already are banned in parts of Europe).
To understand just how revolutionary LED light bulbs are and why they’re still expensive, it is instructive to look at how they’re manufactured and also to compare this to the manufacture of incandescent bulbs. This article explores how incandescent light bulbs are made and then contrasts that procedure with a description of the typical production process for LED light bulbs. So, let us begin by taking a look at how traditional incandescent light bulbs are manufactured. You will find this really is a classic example of an automated industrial process refined in over a century of expertise.
While human incandescent light bulb forms differ in size and wattage, all of them have the three basic components: the filament, the bulb, and the base. The filament is made from tungsten. While very fragile, tungsten filaments can withstand temperatures of 4,500 degrees Fahrenheit and over. The linking or lead-in cables are generally made from nickel-iron wire. This wire is dipped to a borax solution to make the wire more adherent to glass. The bulb itself is made from glass and contains a mixture of gases, generally argon and nitrogen, which increase the life span of the filament. Air is pumped from the bulb and replaced using all the gases. A standardized base retains the whole assembly in place. Aluminum is used on the exterior and glass used to insulate the inside of the base.
Initially produced by hand, light bulb manufacturing is currently almost completely automated. |} First, the filament is manufactured using a process known as drawing, in which tungsten is mixed with a binder material and pulled through a die (a shaped orifice) to a fine wire. Next, the wire is wound around a metal bar called a mandrel in order to mold it to its appropriate coiled shape, and after that it is heated in a process known as annealing, softening the wire and leaves its structure more uniform. The mandrel is then dissolved in acid. Second, the coiled filament is attached to the lead-in cables. The lead-in cables have pins at their ends which are either pressed on the conclusion of the filament or, in bigger bulbs, spot-welded.
Third, the glass lamps or casings are produced using a ribbon system. After heating in a furnace, a continuous ribbon of glass moves along a conveyor belt. Precisely aligned air nozzles blow the glass holes at the conveyor belt to molds, creating the casings. A ribbon machine moving at high speed can create greater than 50,000 bulbs per hour. Following the casings are dismissed, they are chilled and then cut off from the ribbon system. Next, the inside of the bulb is coated with silica to eliminate the glare caused by a luminous, discovered filament. The label and wattage are then stamped onto the exterior top of each casing.