Incandescent Light Bulb Production

Overview

• Incandescent light bulbs are simple devices consisting of a glass bulb, a metal filament, and electrical components.
• The production process involves two main lines: one for the glass bulb and one for the electrical components (mount).

Components of the Bulb

• Base: Contains two metal contacts that connect to the filament.
• Filament: Made of tungsten, it vibrates and emits visible light when heated.

Production Process

Glass Tube Preparation

• Cutting: Glass tubing is cut into specific lengths.
• Glazing: Tubes are passed through a gas flame to smooth the surface.

Mount Manufacturing

1. Flare Making: Tubes are heated until malleable, then stretched into a flared shape.
2. Adding Wires and Exhaust Tube:
   • Two copper lead wires are inserted into the flared end.
   • A thin glass exhaust tube is added.
   • Air is removed via the exhaust tube later during the process.
3. Lead Wire Separation: Wires are separated and formed into hooks to attach to the filament.
4. Coating: Lead wires are coated in zirconium to enhance moisture resistance.

Bulb Creation

• Material: Bulbs are made from soda-lime glass.
• Stamping: Each bulb is stamped with voltage, wattage, and company logo.

Coating for Opaque Bulbs

• Clear bulbs are coated with synthetic silica (white powder) using a charged coating machine.
• Process involves heat and electrical charge to attach the powder to the glass.

Merging Production Lines

• Fusing: Bulb and mount are fused together using torches.
• Sealing: Air is vacuumed out and replaced with argon gas to help filament longevity.
• Base Installation: Aluminum base is added with lead wires soldered in place to create contact points.

Quality Assurance

• Flash Testing: Bulbs undergo repeated light-ups with higher voltage to strengthen filaments before packaging.