Television Manufacturing Processby Contributing WriterUpdated July 21, 2017
Types of Televisions
There are two popular types of televisions. The style most viewers are familiar with is the tube-based television which is made of a glass tube placed in a plastic enclosure. The second style is the flat-screen or high-definition television that is made out of thin glass and liquid crystals.
How Are Tube-Based TVs Made?
Tube based television begin with a series of parts. The materials required include: the plastic enclosure, audio and speaker system, a picture tube, and a collection of electronics. The process begins with the construction of the television's enclosure/housing. Injection molding is used to shape the plastic casing to fit the television. After the mold is created it is trimmed, cleaned, and sanded to make sure the edges fit together perfectly.
The next step is the construction of the picture tube. The CRT (cathode ray tube) is made of glass that is carefully shaped to have a slight curve. The glass is then coated in a special chemical compound and then covered with a thin film of aluminum that allows electrons to pass through to prevent light reflecting into the tube.
The sound portion of the television is usually manufactured as one part. The necessary electronics are connected together and attached to a pair of speakers that fit inside of the casing. The audio system is usually specific to the brand and made by the manufacturer.
Finally, the electronic components are attached to each other. These parts are usually a combination of circuits, chips, and wiring that is custom made by the company. These parts usually differ based on the company and determine the different levels of quality in the television. After all of the parts are created, they are assembled inside of the casing, tested for quality control, and packaged for shipping.
How are Flat Screen TVs Made?
First, a large sheet of glass is cut to the size of the television's screen. This sheet is usually made up from a much large sheet that is cut into several different pieces. After the glass is cut, two panels are placed together. In between the panels, a special gas is added that reacts to electricity. Three different sections are created, one red, one green, and one blue. Each color combine to form the image on the screen.
After the glass and gasses are placed together, they are sent on to a machine that adds chemicals to the glass. These chemicals are used to protect the integrity of the glass. Afterward, custom printed circuit boards are added. Each circuit is designed to send electricity to a pixel on the screen.
Once the screen is complete, all of the additional components are added. The speakers, control modules (for the remote and inputs), and casing are placed together completing the television set. Finally, the television goes through a testing process to ensure its quality. Afterward it is packaged and shipped out to stores and customers.