In the production of light bulbs, one of the critical steps is the soldering of the lamp cap to the electrode lead wire, ensuring a secure and reliable electrical connection. This process involves several precise steps and the use of specific materials and equipment to guarantee the bulb functions correctly and meets quality standards.

Preparing the Solder Material

The first step in the soldering process is to prepare the solder material, which is typically a tin-lead alloy or similar materials that offer desirable properties for welding. These alloys are chosen for their relatively low melting point, which facilitates a smoother, more controlled process. the solder material provides excellent conductivity and fluidity, ensuring a strong electrical connection between the components. The ease with which the solder flows is crucial for forming a consistent joint.

Inserting the Guide Wire

Before beginning the soldering process, the guide wire, also known as the electrode lead wire, is carefully inserted into the corresponding hole of the Infrared Heat Lamp. This positioning is critical for ensuring the alignment of the components during welding, as the guide wire needs to be securely attached to the lamp cap to establish a stable electrical connection once the soldering is completed.

Application of Flux

Once the materials are in place, the next step involves applying flux to the welding area. Flux serves several important functions in the soldering process. It removes any oxides from the metal surface, which can inhibit proper solder adhesion, and it prevents the formation of cold solder joints, which can lead to poor electrical contact. Furthermore, flux helps the solder to flow more easily, ensuring a more uniform coverage of the joint and enhancing the quality of the final weld.

Heating and Soldering

With the materials in place and flux applied, the next step is to heat the welding area using a precisely controlled soldering device. Depending on the production line, this may involve high-frequency induction heating or heat conduction soldering devices. These devices are designed to quickly and evenly raise the temperature to the melting point of the solder, ensuring that the solder flows uniformly across the joint.

Once the solder reaches its melting point, the solder wire is introduced to the heated area. As the solder melts, it flows around the connecting part of the guide wire and lamp cap, forming a solid and reliable electrical bond. The precise control of temperature and solder application ensures that the connection is both mechanically secure and electrically conductive.

Quality Control

After the soldering is completed, the quality of the solder joints is carefully inspected. This is a critical step in the production process, as any imperfections can lead to electrical failures or defects in the final product. Automatic inspection systems are commonly used for this task, such as optical inspection equipment that visually checks the solder joints for consistency, or electrical performance inspection equipment that verifies the conductivity and functionality of the solder connections.

Key quality indicators for the solder joints include smooth and round finishes without the presence of cold solder joints, leaking solder, or spikes. Cold solder joints can cause poor electrical contact during the bulb's operation, leading to malfunction or failure. Spikes or irregularities in the solder joint may result in short circuits, which could jeopardize the safety and functionality of the light bulb.

The whole process requires that the welding is firm, the solder joints are smooth and round, and there are no cold solder joints, leaky solder joints or spikes. Cold solder joints may cause poor contact when the bulb is working, and spikes in the solder joints may cause quality problems such as short circuits. After welding is completed, the solder joints must be inspected for quality through an automatic inspection system, such as optical inspection equipment or electrical performance inspection equipment.

Process-related video: The process of installing the lamp holder and soldering the lamp holder during the production of the light bulb