Term paper report on

MANUFACTURING OF GLASS BULBS

Submitted to
Amity University Uttar Pradesh

In partial fulfillment of the requirements for the award of the

degree of
Bachelor of design
Industrial Product designing by
PRERNA AWASTHI (A21100919038)
Under the guidance of
MR. VIJAY CHAUDHARY
AMITY SCHOOL OF DESIGN
AMITY UNIVERSITY UTTAR PRADESH
JULY 2020
 Declaration
I Prerna Awasthi hereby declare that the project titled
MANUFACTURING OF GLASS BULBS which is submitted
by me to department of Amity School of design , Amity
University Uttar Pradesh, Noida, in partial fulfillment
requirement for the award of the degree bachelor in Design, has
not been previously formed the basis for the award of any
degree, diploma or other similar title or recognition.
The author attests that permission has been obtained for the use
of any copy righted material appearing in the dissertation /
project report other than brief except requiring only proper
acknowledgement in scholarly writing and all such use is
acknowledge.

Date:
15/05/2020
A21100919038

1
 CERTIFICATE

This is to certify that Ms. Prerna Awasthi student of B.des

Product Design has carried out work presented in the project of
the term paper entitle “MANUFACTURING OF GLASS
BULBS” as a part of academic of Bachelor in Product Design
from Amity University, Uttar Pradesh, Noida under my
supervision.

………………………

MR. VIJAY CHAUDHARY

ASD, Noida

2
ACKNOWLEDGEMENT

The satisfaction that accompanies that the successful completion

of any task would be incomplete without the mention of people
whose ceaseless cooperation made it possible, whose constant
guidance and encouragement crown all efforts with success I
would like to thank my faculty guide MR. VIJAY
CHAUDHARY who is the biggest driving force behind my
successful completion of the project. He has been always there
to solve my query of mine and also guided me in the right
direction regarding the project. Without his help and inspiration,
I would not have been able to complete the project. Also I
would like to thank my batch mates who guided me, helped me
and gave ideas and motivation at each step.

…………………..
PRERNA AWASTHI

3
 INDEX

S.NO TOPIC PAGE NO. SIGNATURE

1 Declaration 1

2 Certificate 2

3 Acknowledgement 3

4 Table to content 4

5 abstract 5

6 Introduction 6-7

7 History 8

8 The 9
manufacturing
process
9 Filament 10

10 Glass bulb 11

11 Base 12

12 Assembly 13

13 Conclusion 14

14 Reference 15
 ABSTRACT

This report describes the manufacturing of incandescent bulbs.

Talking about the production processes, so processes are divided
between two production teams. One team works on the outside
glass of a bulb whereas other team works on the inside parts of
an incandescent bulb.

5
 INTRODUCTION
Thereiareidifferentitypesiofibulbsilikeiincandescent,iCFL,iHalogeni
andiLED.iIncandescentibulbsiareilessiefficientithaniotheritypesiof
ibulbsibecauseitheyiconvertilessithani5%iofienergyitheyiuseiintoi

visibleilight.iButitheiincandescentibulbsiareisecondimostiusedilamp
sibehindifluorescentilamps.iIncandescentibulbiwasitheisecondiform
iofielectricilightiwhichiwasidevelopediforicommercialiuseiafterithei

carboniarcibulb.iIncandescentibulbsiareimadeiiniwideirangeiofisize
s,ilightioutputiandivoltageiratingsifromi1.5ivoltsitoiabouti300ivolts.i
Theyidon’tirequireianyiexternaliregulatingiequipmentiandialsoi
haveilowimanufacturingicost,iandiworksiequallyiwellioni
alternatingicurrentioridirecticurrent.

6
Theitraditionaliincandescentibulbsiareinotionlyilightisourceibutialso
ihasibecomeiaisymboliofiinnovation.iIncandescentibulbsiareinotiini

muchiuseitheseidaysievenitheyiareibannediinimanyicountries
ibecauseiofitheiriinefficiency.iTheiincandescentibulbsiareireplacedi

byiLEDibulbsinow.i

7
 HISTORY
Theiseedsiofitheilightibulbilieiinitheidevelopmentiofithei
incandescentilamp.iIni1809,iHumphreyiDavyiusediaihighpower
ibatteryitoigenerateielectricicurrentibetweenitwoistripsioficharcoal.i

Theihighamountiofiheatigeneratedibyitheicurrentiflowingithroughi
thei charcoalistripsimadeithemiglow.iThisiwasitheicarboniarcilamp.

Ini1820,iWarrenideilaiRueiattempteditoiinventitheiveryifirsti
incandescentilamp.iHeiinsertediaiplatinumifilamentiinsideiaipartial
lyivacuumediglassitubeiandichanneledielectricicurrentithroughiit.i
Theihighiheatigeneratedimadeitheimetaliglowiandiproduceilight.
iRueiusediplatinumibecauseitheimetal’sihighimeltingipointiprevent

ediitifromidisintegratingiatihighitemperatures.iHeiusediaipartiallyi
vacuumeditubeitoiminimizeitheichancesiofigasiparticlesireactingi
withitheiheatedimetal.iRue’simeasureiensuredithatitheiplatinumi
wasistableiandilastediailongitime.

8
THE MANUFACTURING
i i

PROCESS
Theiusesiofilightibulbsirangeifromistreetilightsitoiautomobilesihead
lightsitoiflashlights.iForieachiuse,itheiindividualibulbidiffersiinisizei
andiwattage,iwhichidetermineitheiamountiofilightitheibulbigivesioff
.iHowever,ialliincandescentilightibulbsihaveitheithreeibasicipartsith
eifilament,itheibulbianditheibase.iOriginallyiproducedibyihand,ithei
lightibulbimanufactureiisinowialmostientirelyiautomated.

9
Filament

 Theifilamentiisimanufacturedithroughiaiprocessiknowniasi
drawing,iiniwhichitungsteniisimixediwithiaibinderimaterial
iandipulledithroughiaidieiaishapediorifice-intoiaifineiwire.i

 Next,itheiwireiisiwoundiaroundiaimetalibaricallediaimandrel
iiniorderitoimoldiitiintoiitsipropericoiledishape,ianditheniitiis

iheatediiniaiprocessiknowniasiannealing.iThisiprocessisoftensi

theiwireiandimakesiitsistructureimoreiuniform.iTheimandreli
isithenidissolvediiniacid.

 iTheicoiledifilamentiisiattacheditoitheilead-iniwires.iTheilead-
iniwiresihaveihooksiatitheiriendsiwhichiareieitheripressedi
overitheiendiofitheifilamentior,iinilargeribulbs,ispot-welded.

10
Glass bulb
i

 iTheiglassibulbsioricasingsiareiproducediusingiairibboni
machine.i
 aifurnace,iaicontinuousiribboniofiglassimovesialongia
iconveyoribelt.iPreciselyialignediairinozzlesiblowitheiglassi

throughiholesiinitheiconveyoribeltiintoimolds,icreatingithei
casings.iAiribbonimachineimovingiatitopispeedicaniproducei
moreithani50,000ibulbsiperihour.iAfteritheicasingsiareiblown,
itheyiareicoolediandithenicutioffiofitheiribbonimachine.iNext,i

theiinsideiofitheibulbiisicoatediwithisilicaitoiremoveitheiglarei
causedibyiaiglowing,iuncoveredifilament.iTheicompanyi
emblemiandibulbiwattageiareithenistampediontoitheioutsidei
topiofieachicasing.

11
Base

 iTheibaseiofitheibulbiisialsoiconstructediusingimolds.iItiis
imadeiwithiindentationsiinitheishapeiofiaiscrewisoithatiiticani

easilyifitiintoitheisocketiofiailightifixture.

12

ASSEMBLY
  iOnceitheifilament,ibase,iandibulbiareimade,itheyiareifittedito
getheribyimachines.iFirst,itheifilamentiisimounteditoitheistem
iassembly,iwithiitsiendsiclampeditoitheitwoileadiniwires.i

Next,itheiairiinsideitheibulbiisievacuated,iandithei
casingiisifillediwithianiargoniandinitrogenimixture.iTheseigas
esiensureiailongerlifeiforitheifilament.iTheitungsteniwillieven
tuallyievaporateiandibreak.iAsiitievaporates,iitileavesiaidark
idepositionitheibulbiknowniasibulb-walliblackening.

 Finally,itheibaseianditheibulbiareisealed.iTheibaseislidesiontoi
theiendiofitheiglassibulbisuchithatinoiotherimaterialiisineededi
toikeepithemitogether.iInstead,itheiriconformingishapesi
allowitheitwoipiecesitoibeihelditogetherisnugly,iwithitheilead-
iniwiresitouchingitheialuminumibaseitoiensureiproperielectric
alicontact.iAfteritesting,ibulbsiareiplacediinitheiripackagesi
andishippeditoiconsumers.

13

Conclusion
Theifutureiofitheiincandescentilightibulbiisiuncertain.iWhile
i heatingiaifilamentiuntiliitiglowsiisicertainlyiaisatisfactoryiwayito
i produceilight,iitiisiextremelyiinefficient:iabouti95ipercentiofithei
electricityisupplieditoiaitypicalilightibulbiisiconverteditoiheat,inot
i light.iIniaiworldiwithidwindlingiresources,iwhereienergyi
conservationiisiincreasinglyivital,ithisiinefficiencyimayieventuallyi
makeitheiincandescentilightibulbiimpractical.

Thereiareiotherilightisourcesialreadyiiniuseithaticouldisupplantithei
incandescentibulb.iFluorescentitubes,iforiinstance,ialreadyi
dominateitheiindustrialimarket,iandiundoubtedlyitheyiwillifindi
increasingiuseiasiaidomesticilightisourceiasiwell.iFluorescentibulbs
i useiatileasti75ipercentilessienergyithaniincandescentibulbsiandican
i lastitwentyitimesilonger.iTheirecentidevelopmentiofi"compact"I
fluorescentibulbs,iwhichiunlikeitheistandardifluorescentitubeicani
screwiintoiaitypicalidomesticilamp,imayiexpanditheidomestic
i marketiforifluorescentilighting.

14

Reference
1. Werner Vogel: "Glass Chemistry"; Springer-Verlag
Berlin and Heidelberg GmbH & Co. K; 2nd revised
edition (November 1994), ISBN 3-540-57572-3
2. The dilatometric softening point is not identical with the
deformation point as sometimes presumed. High
temperature glass melt property database for process
modeling; Eds.: Thomas P. Seward III and Terese Vascott;
The American Ceramic Society, Westerville, Ohio,
3. B. H. W. S. de Jong, "Glass"; in "Ullmann's Encyclopedia
of Industrial Chemistry"; 5th edition, vol. A12, VCH
Publishers, Weinheim, German

15