These blade-type car fuses from Wenzhou Tianwei of mainland China have a current load capacity of between 20 and 100A.

Blade models one-third the size of standard types have a power capacity of 35A, backing up more applications.

Fuses from Taiwan and mainland China are becoming smaller yet more powerful as makers address the need for greater circuit protection to support the growing number of electronic automotive applications.

Aside from conventional applications such as ECUs and body-control modules, a range of high-tech accessories for security, navigation and in-car entertainment systems are becoming standard in many vehicles. This comes as recent studies show that electronics now account for 20 and 31 percent of the total cost of compact and luxury cars, respectively.

According to suppliers interviewed, passenger cars now require an average of 40 fuses, double that of two years ago. This has consequently spurred demand for compact fuses that can fit easily into fuse boxes even when installed in large quantities.

The high-end segments of Japan, Europe and the US are the main markets of such models.

Taiwan makers, in particular, are undertaking downsizing projects to boost exports. The majority of companies are focusing on mini blade fuses 200 and 100 percent smaller than previous maxi and standard sizes, respectively. These have amperage ratings ranging from 2 to 35A, allowing for safer current regulation even at higher power loads.

Blade fuses dominate production in the island, practically phasing out glass tube and ceramic types. Housed in high-grade plastic and fitted with zinc alloy links, blade types are favored by car assemblers both locally and overseas for their strength and higher breaking capacity.

Makers said they are also investing in technology upgrades that will allow them to produce even smaller models with the same power capacity as that of maxi-size fuses, or about 100A.

In the mainland, although many suppliers now have the capability for blade fuse production, glass tube types are still widely manufactured, and in fact constitute about half of total output.

Glass tube models entail only about 50 percent of the production cost of blade fuses, and as such allow makers to offer lower prices.

The strategy also enables companies to sustain strength in the low end and midrange while developing new products for the upscale segment.

Moreover, mainland suppliers are increasingly obtaining international quality certification to gain an edge over competitors.

Products from companies featured in this report generally have CE, CCC, UL and VDE certification, and comply with the RoHS directive.

	The model ATS plug-in blade fuse from Zeeman of Taiwan meets the SAE standard. It is housed in PC resin and comes with a zinc alloy fuse link.

According to suppliers, miniaturization is critical now with the increasing number of fuses that high-end car models require. And even with more electronic applications to support, the fuse boxes that contain them remain the same in size or are smaller, following the compact trend in passenger cars.

The latest plug-in mini blade fuses from Zeeman Industry Co. are 30 percent thinner than a similar product series that the company released last year. The line will be upgraded further by 2008.

Zeeman said it would eliminate the two tin terminals found in its current fuse design, decreasing size by 50 percent. Despite the reduction in dimensions, the load capacity stays the same at 2, 3, 3.5, 7.5, 10, 15, 20, 25, 30 and 35A.

To ensure reliable performance while downsizing, Zeeman employs imported equipment in production. It is also currently building a factory for the manufacture of even smaller and thinner fuses with improved zinc alloy fuse elements. The new plant is expected to double the company’s capacity and help accommodate volume OEM orders.

Conquer Electronics Co. Ltd offers mini ATM and standard blade fuses for low-current automotive functions such as ECUs and gauges. Over recent months, the company has also launched models that can support navigation, communication, security and in-car entertainment systems and other advanced electronic peripherals.

To meet the high levels of power required in such functions, Conquer has developed the PSP and PMP series. Models in this category have a capacity of up to 250V.

These have obtained UL, CE, VDE, PSE, CCC, CSA certification and comply with the RoHS directive.

Photo-top Technologies Co. Ltd has introduced self-diagnostic blade fuses. These have LED indicators that light up when the fuse needs replacement before it blows.

Manager Michael Chen said that besides circuit protection, this technology simplifies the detection of potential car problems even in the absence of testing equipment.

Photo-top will be releasing a series of high-power fuses next year. The line will have a load capacity of at least 100A, but with dimensions similar to the compact blade fuses it currently offers.

The company said the high-power design is in its final R&D stage, and then will be subjected to testing and certification.

Che Yen Industrial Co. Ltd has been making fuses for more than 20 years, and now offers various blade models. The company will be expanding its product range to include components and accessories such as fuse links and holders to boost margins.

	Models in the ATP series of Taiwan-based Photo-top have LED indicators that light up when the fuse element blows.

To gain an edge amid a continuing price war in the low end, mainland suppliers of car fuses are keen on improving product quality. Makers are also working toward expanding market reach by offering a diversified selection.

Shenzhen Wandiantong Electronic Technological Co. Ltd uses locally sourced materials that are inspected prior to production. The company ensures that the lead content of its models is within the levels required by the RoHS directive. Models also meet UL and VDE requirements.

Shenzhen Wandiantong now uses zinc alloy instead of copper for the inner fuse of its tube models, increasing breaking capacity. The glass housings have nickel-plated end caps.

Comarch Industrial Co. Ltd recently purchased automatic production equipment that facilitates precise surface-mounting and components assembly.

The company manufactures glass tube, blade, fork-terminal and Eastern Europe terminal-compatible car fuses. These come in voltage ratings of 12, 24 or 32V, and have a current load capacity of between 2 to 100A.

Product development efforts center on ceramic car fuses.

Wenzhou Tianwei Car Fitting Fty is among the mainland companies shifting their attention to blade fuses, which now account for 50 percent of the company’s total output. Tube and Eastern Europe versions are also offered.

Wenzhou Tianwei recently launched a selection of ceramic designs, which are marketed as high-end models. The line now takes up 10 percent of production.

Changzhou Lingguang Industrial General Co. is also venturing into the ceramic tube fuse line, although glass tube models are still produced.

The supplier is beginning to target the midrange and high-end markets. Exports now go to the US and developing countries in Europe.

It plans to increase prices slightly by 5 percent or less to offset the rising cost of ceramic and zinc alloy.

Products have CE and UL certification and are compliant with the RoHS directive.