Emphasis on greater versatility, durability

	Auto Dragons uses SMD LEDs in its latest models for daytime running lights.

China suppliers of automotive bulbs are introducing design and performance upgrades to align their selections with international road safety regulations and vehicle styling trends.

Efforts are particularly aggressive among manufacturers in the LED line. Most are rushing to meet demand for models compatible with daytime running lamps, which switch on automatically once the engine is started to increase visibility even under direct sunlight.

This is in response to the EU mandate requiring the installation of DRLs on all new passenger vehicles and small delivery vans beginning Feb. 7, 2011. The same will be enforced on trucks and buses from Aug. 7, 2012 and onwards.

Up to 90 percent more energy-efficient, LED bulbs are generally preferred over their halogen counterparts when it comes to DRLs. Fuel consumption is a key concern in such applications because the power to run the unit must be produced by the engine.

To improve marketability further, manufacturers are rolling out more durable models. With thermal emission upgrades in place, new releases last signifi cantly longer at 50,000 to 100,000 hours.

Companies are also heeding DRL concerns on design flexibility. Some are tapping SMD LEDs to develop compact constructions. The one-diode versions, in fact, can be fitted with bases measuring only 2.5x10mm.

SMD variants are being adopted as well to produce flexible LED strips for DRL assemblies. Measuring 28cm long, standard 3W models are equipped with 15 diodes, each rated at 3,200mcd, which equals the brightness of xenon bulbs. Prices range from $2.50 to $4.

Suppliers are likewise relying on LED strips to catch the attention of car-tuning enthusiasts. This type of configuration has actually paved the way for new types of decorative lighting.

For instance, 24cm-long models fi tted with 24 SMD LEDs are meant for installation on grille guards, in trunks and even the top curve of headlamps. Those in red go for $1 to $2. Blue and purple versions are at least 10 and 20 percent more expensive.

Counterparts extending to between 72 and 96cm are sized specifically for wheel rims.

Shenzhen Watt Auto Electrical Co. Ltd offers a 5m model that can be mounted under body kits. Rated at 12V and below 1W, the unit adopts white, blue, red, green or yellow diodes.

For the auxiliary lighting segment, suppliers are reworking designs so these can be utilized as halogen bulb replacements.

For dome, door, dashboard and license plate applications, Shenzhen Watt has launched mini cylinder-shaped models with one to three 1W LEDs and an SV8.5 base.

A few suppliers have even ventured into LED bulbs for CAN bus systems. Many of the units are specifically designed to heed demands of BMW car owners at home and abroad. Shenzhen Hongweida Electronices Co. Ltd is working on designs with safer operating temperature of 60 to 70 C.

As for traditional incandescent and halogen bulbs, laws restricting the use of HID headlights are spurring developments. Such regulations are currently in place in Brazil and Russia. A similar policy is expected to be launched in Turkey in the months ahead.

To enhance the heat and shock resistance of glass envelopes, incandescent bulb manufacturers are purchasing automatic encapsulation lines from the US, Germany or Singapore. Units made using such facilities last 200 hours longer than traditional models, allowing for up to 500 hours of operation.

Halogen bulb suppliers are boosting high temperature tolerance, and scratch and UV protection via ultrathin nanometer coating. Compared with micrometer-thick finishes, this alternative permits more color variations and greater fade resistance.

Despite the sanctions on HID headlights, R&D on compatible bulbs remains active, as the popularity of vehicle styling solutions is sustaining demand.

Companies’ latest efforts have taken energy transfer efficiency rates from 82 to 85 percent. Input voltage ratings have widened to between 9 and 32V, making models suitable for 12V car and 24V truck applications.

In terms of production, turnout in HID headlamp line has been climbing 10 to 20 percent annually for the past three years.

Products & prices
Industry demographics

	Shenzhen Watt’s FE4 11x30-44 model can be adopted in dome, dashboard, door and license plate lights.

Half of shipments are incandescent and halogen units. LED and HID models account for 30 and 20 percent.

Suppliers usually offer just one category, although selections at some midsize and large companies consist of two or more types.

The LED and HID segments are gaining the most momentum, with growth spurred by demand for energy-efficient and durable solutions. Production is also getting a boost thanks to advancements in domestic technologies, which in turn made key components such as ballasts and chips more accessible and affordable.

Pricewise, the maturing supply chain has paved the way for reductions. The first half of 2010 saw quotes for LED and HID designs drop by at least 5 and 10 percent, respectively. Additional cuts are expected in the months ahead.

Although out of the spotlight, the incandescent and halogen lines continue to have the upper hand in terms of preinstalled bulbs for low-end and midrange vehicles. This is attributed in large part to the fact that filament-type units remain less expensive.

Headlight-compatible halogen models, for instance, are available at less than half the quotes of HID counterparts.

Incandescent bulbs for taillights range only from $0.01 to $0.50, while LED versions start at $1.

In coming months, prices of incandescent and halogen designs are likely to stay at current levels or even decline a bit depending on the material cost situation.

Quotes across all segments also differ based on power rating, grade and source of components, and lifespan.

Incandescent bulbs: China-made models are rated from 6 to 24V and 1 to 130W. Those for headlamps are available in the H1, H3, H4, H7 and H13 series. Versions compatible with tail- and exterior auxiliary lights have S25, G18 and G40 bases. Interior use options include T5 and T10 units.

The line is offered in single- and double-filament designs. Glass or quartz is adopted for the envelope, which can come in red, orange, yellow, green or blue.

The filaments are often procured domestically. Variants from Germany, Japan and Taiwan are only seen in upscale models.

Service life falls below 500 hours for low-end units, which are priced at less than $0.12. Versions reaching $0.55 and $1.50 last up to 800 and 1,000 hours.

Application-wise, designs for headlamps are $5 per pair.

Halogen bulbs: The selection consists of single- and double filament designs in the H1, H3, H4, H7 and H13 series. Models are rated between 55 and 130W.

The least expensive units go for about $0.40. These are fitted with nickel-plated iron bases and stainless steel shields.

Both inputs are usually sourced from Zhejiang and Jiangsu provinces.

Versions quoted up to $70 have molybdenum shields, which companies often purchase in Shanghai and Hubei province.

Above this price point, keycomponents are either imported directly or procured from foreign-invested enterprises based in mainland China. For filaments, manufacturers turn to South Korea, Taiwan and Japan. Schott AG of Germany provides the bulk of the glass tube requirement.

HID bulbs: The line is similarly available in the H and 900 series with power ratings from 21 to 550W. Models at the lower end of the price spectrum last for less than 2,000 hours. Upscale counterparts go beyond 5,000 hours.

Color temperature is between 4,300 and 12,000K. Designs at 6,000K generate a bright white light. Those below this level emit a yellow beam, providing better visibility through fog or in the rain. While suppliers continue to offer standalone bulbs, conversion kits already dominate the segment with an up to 70 percent share of exports.

For the latter, the light source and ballast represent one-half and one-third of each set’s cost.

Models go for $30 to $300. Most use domestic bulbs, although suppliers also turn to Osram, Philips or GE for upscale designs. The ICs are typically made in the US, the EU or Japan. The bases are purchased in Jiangsu and Zhejiang.

With ballasts, at least 60 percent of manufacturers are tapping units that measure only 12 or 13mm-thick. This version is two or three times more compact than traditional types.

All-in-one solutions, which are suitable for most car brands and models, exceed $60. Ballasts used for this type are fitted with a coil for eliminating interference from electromagnetic waves and high voltage.

Such aftermarket kits are said to match the performance of preinstalled counterparts. Fewer than fi ve companies, however, are currently engaged in production. All are located in Guangdong province.

LED bulbs: Models for tail and auxiliary lamps dominate output in this segment. Headlamp-compatible versions are at the R&D stage.

Available from 0.1 to 3W, units have efficiency ratings of between 40 and 144 lm/W. The latest 1W releases reach 80 to 90 lm/W.

Designs in white, blue, green, yellow and red are offered. Most last 10,000 to 50,000 hours. Models are often positioned in the midrange and high end.

LED bulbs priced $0.05 or below per unit use domestically sourced chips. Variants from Taiwan are adopted in models that go for as much as $0.10.

More-expensive designs are fitted with US- or Japan-made chips.

Domestic versions are likely to gain ground following the release in January of the first set of locally developed LED chip manufacturing equipment in Foshan, Guangdong province. Units will enter commercial production within this year.

China hosts 1,500 or so suppliers of automotive bulbs. The pool for filament-type and HID units has been relatively stable, comprising 1,000 and 100 enterprises, respectively.

The LED segment has been expanding, with 50 new entrants in the past two years. Its present manufacturing base stands at 500 companies.

Capability-wise, small enterprises represent more than 60 percent of the industry. Among such businesses, the workforce does not exceed 500 and annual capacity falls below 500,000 units. Assembly is conducted in-house, with all major components outsourced.

Approximately 30 percent of companies are midsize. Their factories can produce between 500,000 and 1 million units each year. Up to 1,000 personnel handle operations, including a 20 to 50-member R&D team.

Larger players represent 5 percent of the supplier pool, most of which are either foreign-invested or state-owned. Companies of this scale are able to roll out more than 1 million units annually, a portion of which goes directly to automakers.

At some midsize and large factories, production lines for key inputs such as ballasts and glass tubes are in place. QC facilities frequently include photometers for testing luminous intensity. A handful of businesses also employ goniophotometers, which provide high-precision measurements of light distribution.

In terms of location, plants are scattered in Guangdong and the Yangtze River Delta region, where a network of car assemblers and a well-developed infrastructure support production.

Guangdong is particularly strong in the LED line, with designs targeting the upscale segment.

Output in the Yangtze River Delta consists mostly of halogen and HID units.