LED tube lights are made by assembling a printed circuit board (PCB) or similar structure with LEDs and electronic components that convert AC voltage to the DC voltage required to power the LEDs.
Here's a breakdown of the LED tube light manufacturing process:
Core Components
- LEDs: These are the light-emitting diodes that produce the light. They are surface-mounted to the PCB. Different types of LEDs, varying in brightness and color temperature, may be used.
- Printed Circuit Board (PCB): This board serves as the foundation for mounting the LEDs and other electronic components. It provides the electrical connections between components.
- Driver Circuit (Power Supply): This electronic circuit converts the AC mains voltage into the DC voltage required by the LEDs. It also regulates the current flowing through the LEDs to ensure consistent brightness and prevent damage.
- Housing (Tube): The housing is typically made of glass or polycarbonate and provides protection for the internal components. It also helps to diffuse the light evenly.
- End Caps: These provide the electrical connections to the power source and secure the tube in place.
Manufacturing Steps
- PCB Design and Fabrication: The PCB design is created using CAD software, and then the PCBs are manufactured. This involves etching the copper traces onto the board and drilling holes for the components.
- Component Mounting (SMT): LEDs and other electronic components are surface-mounted onto the PCB using automated machines in a process called Surface Mount Technology (SMT).
- Soldering: The mounted components are soldered to the PCB to ensure proper electrical connections. This can be done using reflow soldering or wave soldering.
- Driver Circuit Assembly: The driver circuit is assembled, tested, and connected to the PCB.
- Housing Assembly: The PCB with the LEDs and driver circuit is inserted into the housing.
- End Cap Installation: The end caps are attached to the housing and connected to the electrical connections on the PCB.
- Testing and Quality Control: The finished LED tube light is tested to ensure that it meets performance and safety standards. This includes testing for light output, color temperature, power consumption, and safety certifications.
- Packaging: The tested and approved LED tube lights are packaged for shipment.
In summary, the process involves assembling LEDs and electronic components onto a PCB, housing them in a protective tube, and ensuring proper electrical connections and functionality through testing and quality control.
