Large Globe Light Bulbs – One-hundred-and-thirty ages ago, Thomas Edison finished the first successful sustained test of the incandescent light bulb. With some incremental improvements along the way, Edison’s fundamental technology has emphasized the world ever since. This is all about to change. We’re on the cusp of a semiconductor-based lighting revolution that will ultimately replace Edison’s bulbs using a far more energy-efficient lighting solution. Solid state LED lighting will gradually replace almost every one of the countless billions of fluorescent and incandescent lighting being used around the world today. In fact, as a step along this route, President Obama last June introduced new, more rigorous lighting standards that will support the phasing out of incandescent bulbs (which are banned in parts of Europe).
To understand exactly how revolutionary LED light bulbs are as well as why they are still expensive, it is 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 made then contrasts that procedure with a description of the typical production process for LED light bulbs. So, let us start by having a look at how traditional incandescent light bulbs are manufactured. You’ll find this is a classic instance of an automatic industrial process refined in over a century of expertise.
While individual incandescent light bulb forms differ in size and wattage, all of them have the 3 basic parts: the filament, the bulb, and also the base. 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 generally made of nickel-iron cable. This cable is dipped to a borax solution to generate the cable more adherent to glass. The bulb itself is made of glass and contains a mixture of gases, usually argon and nitrogen, which raise the life of the filament. Air is pumped out of the bulb and replaced using the gases. A standardized base holds the entire assembly in place. Aluminum can be used on the outside and glass used to insulate the inside of the base.
Initially produced by hand, light bulb manufacturing is now almost completely automated. |} First, the filament is fabricated with a process known as drawing, in which tungsten is mixed with a binder cloth and pulled through a die (a shaped orifice) to a fine wire. Then, the cable is wound around a metal bar called a mandrel so as to mold it to its proper coiled shape, then it is heated in a process known as annealing, softening the cable and leaves its construction more uniform. Second, the coiled filament is connected to the lead-in cables. The lead-in cables have hooks at their ends which are either pressed on the end of the filament or, in bigger bulbs, spot-welded.
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 through holes in the conveyor belt to molds, making the casings. A ribbon machine going at top speed can create more than 50,000 bulbs per hour. Following the casings are blown, they are chilled and then cut off from the ribbon machine. Then, the inside of the bulb is coated with silica to eliminate the glare caused by a luminous, uncovered filament. The wattage and label are then stamped on the outside top of every casing.