MANUFACTURING

PROCESS
Led bulbs
Content
• Introduction
• Working principle
• Manufacturing and assembling process
LED bulb
An LED lamp is a light-emitting
diode (LED) product that is
assembled into a lamp (or light
bulb) for use in lighting fixtures.
LED lamps have a lifespan
and electrical efficiency which
are several times greater
than incandescent lamps, and
are significantly more efficient
than most fluorescent lamps
 Working principle
A light-emitting diode (LED) is a two-
lead semiconductor light source. It is a p–n
junction diode that emits light when
activated.[5]When a suitable voltage is
applied to the leads, electrons are able to
recombine with electron holes within the
device, releasing energy in the form
of photons. This effect is
called electroluminescence, and the color of
the light (corresponding to the energy of the
photon) is determined by the energy band
gap of the semiconductor.
Diodes, in general, are made of
very thin layers of semiconductor
material; one layer will have an
excess of electrons, while the next
will have a deficit of electrons. This
difference causes electrons to
move from one layer to another,
thereby generating light.
Manufacturers can now make
these layers as thin as .5 micron or
less
MANUFACTURING AND ASSEMBLING
PROCESS
Raw materials
A semiconductor is a crystalline material that conducts electricity
only when there is a high density of impurities in it. The slice, or
wafer, of semiconductor is a single uniform crystal, and the
impurities are introduced later during the manufacturing process.
Think of the wafer as a cake that is mixed and baked in a
prescribed manner, and impurities as nuts suspended in the cake.
The particular semiconductors used for LED manufacture are
gallium arsenide (GaAs), gallium phosphide (GaP), or gallium
arsenide phosphide (GaAsP).
Design
Several features of the LED need to be considered in its design,
since it is both an electronic and an optic device. Desirable optical
properties such as color, brightness, and efficiency must be
optimized without an unreasonable electrical or physical design.
These properties are affected by the size of the diode, the exact
semiconductor materials used to make it, the thickness of the
diode layers, and the type and amount of impurities used to
"dope" the semiconductor
The Manufacturing
Process
Making semiconductor wafers
First, a semiconductor wafer is made. The particular material composition—GaAs,
GaP, or something in between—is determined by the color of LED being fabricated.
The crystalline semiconductor is grown in a high temperature, high pressure
chamber. Gallium, arsenic, and/or phosphor are purified and mixed together in the
chamber.
Adding metal contacts
Metal contacts are then defined on the wafer. The contact
pattern is determined in the design stage and depends on
whether the diodes are to be used singly or in combination