Fluorescent Drop Light Bulbs – One-hundred-and-thirty ages ago, Thomas Edison completed the first successful ongoing test of the incandescent light bulb. With some incremental improvements on 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 ultimately replace Edison’s bulbs with a far more energy-efficient lighting solution. Solid state LED lighting will gradually replace almost all of the hundreds of billions of fluorescent and incandescent lighting being used around the world today.
To know exactly how revolutionary LED light bulbs are and why they’re still pricey, it is instructive to look at how they’re fabricated and to compare this to the manufacture of incandescent light bulbs. This article investigates how incandescent light bulbs are made then contrasts that process with a description of the typical manufacturing process for LED light bulbs. So, let’s start by having a look at just how traditional incandescent light bulbs are manufactured. You will realize that this is a classic example of an automatic industrial process elegant in more than a century of experience.
While individual incandescent light bulb forms differ in size and wattage, all of them have the three primary parts: the filament, the bulb, and also the foundation. The filament is made of tungsten. The linking or lead-in wires are typically made of nickel-iron cable. This cable is dipped into a borax solution to generate the cable more adherent to glass. The bulb itself is made of glass and contains a combination of gases, usually argon and nitrogen, which raise the life span of the filament. Air is pumped out of the bulb and replaced with the gases. A standardized foundation 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 now almost completely automated. |} Next, the cable is wound around a metal bar called a mandrel in order to mold it into its appropriate coiled shape, after that it is heated in a process known as annealing, softening the cable and makes its construction more uniform. The mandrel is then dissolved in acid. Secondly, the coiled filament is attached to the lead-in wires. The lead-in wires have hooks at their ends that are either pressed on the end of the filament or, in larger bulbs, spot-welded.
Third, the glass lamps 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 holes at the conveyor belt into molds, making the casings. A ribbon machine moving at top speed can create more than 50,000 bulbs each hour. After the casings are blown, they are cooled and then cut from the ribbon system. 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 each casing.