China makers of film capacitors are boosting production for emerging applications while bolstering competitiveness in traditional bases in consumer electronics, power supplies and communication devices. Companies are complementing these initiatives with R&D efforts geared toward raising product performance and reliability.
Manufacturers are preparing for rising demand from the new energy, LED lighting, and hybrid and electric vehicle segments, which account for 30 percent of total output at present. Local companies hope to benefit from the global inverter market, which is projected by Pike Research to grow 164 percent from 2011 and hit $19 billion by 2017. The device used in PV, small wind power, stationary fuel cell and vehicle-to-grid systems is expected to boost the need for film capacitors.
The EV and HEV industry, meanwhile, will roll out 4.9 million units in 2016, or four times the number in 2011. Key player Xiamen Faratronic has invested $18 million to increase capacity for film capacitors targeted at wind converters, EVs and HEVs. Once the project is completed in 1H14, the supplier will be able to handle up to 300 million μFUnit of capacitance. The basic unit of a measure of a capacitor. A capacitor charged to 1 volt with a charge of 1 coulombA coulomb is the unit of electric charge. It is named after Charles-Augustin de Coulomb.1 coulomb is the amount of electric charge transported by a current of 1 ampere in 1 second. It can also be defined in terms of capacitance and voltage, where one coulomb is defined as one farad of capacitance times one volt of electric potential difference. would have a capacitance of 1 farad. 1 microF = .000001 Farads. annually. The company will also construct a 25,000sqm factory in Xiamen, Fujian province, which will be equipped with winding machines and solder assembly lines. This facility is expected to match the first's volume.
Nantong Jianghai has allocated $32 million for the acquisition of 10 new production lines for high-voltage film capacitors. This will also fund R&D efforts for models rated at more than 650V for elevated-voltage inverters, and PV and EV use. The endeavor will boost the maker's yearly capacity to 1 million units for high-voltage types and expand its capacitor lineup. The maker specializes in aluminum electrolyticA polarized capacitor exhibiting a very high capacitanceThat property of a system of conductors and dielectrics which permits the storage of electricity when potential difference exists between the conductors. Its value is expressed as the ratio of a quantity of electricity to a potential difference. A capacitance value is always positive./volume ratio that consists of two electrodes immersed in an electrolyte, with a chemical film that acts as a dielectricThe insulating material between the plates of the capacitor. The material is chosen for its ability to permit electrostatic attraction and repulsion to take place across it. The material will have the property that energy required to establish an electric field is recoverable in whole or in part, as electric energy. In other words, a good dielectric material is a poor conductor of electricity while being an effective supporter of electrostatic fields. on one or both electrodes. Electrolytic capacitors are made by winding either plain or etched foils on which an oxide has been formed on the surface of one (either anodeAn electrodeA solid electric conductor through which an electric current enters or leaves in a medium through which current enters any nonmetallic conductor. or cathodeThe negative electrodeA solid electric conductor through which an electric current enters or leaves in a medium of a capacitor.) film. The etching of the foil increases the surface area and a considerable increase in capacitanceThat property of a system of conductors and dielectrics which permits the storage of electricity when potential difference exists between the conductors. Its value is expressed as the ratio of a quantity of electricity to a potential difference. A capacitance value is always positive. can thus be obtained. kinds.
Small and midsize businesses are likewise implementing expansion plans. Shenzhen Topmay Electronic Co. Ltd has raised monthly output by 10 percent and now churns out 5 million units. The supplier's products suit mainly consumer electronics and LED lights.
Dongguan Easy-Gather Electronic Co. Ltd has increased its turnout by 40 percent from 1H12 figures, yielding about 3.5 million polypropylene film capacitors and 1 million polyester variants each month. Diode-based luminaires and power supplies are the main applications.
In terms of R&D efforts, the emphasis is on high withstand voltage and low loss for enhanced product reliability. Makers are looking to adopt thinner metal foil and metallized film in 3, 4 or 5μm to realize withstand voltage up to 4.5 times the rated voltage from 3 times. Widely available materials are, however, at 6μm. To ensure consistent film thickness, suppliers implement strict IQC and employ advanced winding and cutting equipment.
Shenzhen Shengtai Technology Co. Ltd offers metallized variants delivering 3,000V maximum with 1.75 times withstand voltage. Shenzhen Shanrui Electronics Co. Ltd has units capable of up to 2,000V and can handle more than two times the rated voltage.
To achieve low loss, makers assess the quality of incoming metal materials based on the thickness and electrical properties. They also check for scratches and signs of corrosion.
Film capacitors constitute 10 percent of China's capacitor output, a share predicted to rise to 12 to 15 percent in the months ahead. The estimated volume for 2013 is 36 billion units, up from 33 billion last year and solidifying the country's global hub status for the category.
At present, China is responsible for 40 percent of production worldwide. It exports 50 percent of yield, which is expected to rise by at least 5 percent in 1H13.
The EU, the US, South America, Asia and Africa are the main overseas areas. Makers are also tapping opportunities in emerging markets. Dongguan Easy-Gather, which concentrated on the US, Japan and Switzerland in past years, will increase shipments to Brazil and India by more than 5 percent. Shenzhen Shengtai will continue targeting the EU, the US and Southeast Asia while boosting exports to Western Europe by over 5 percent.
Ceramic, aluminum electrolyte and tantalum kinds make up the rest of China's capacitor selection. The first two remain dominant, collectively accounting for 80 percent of total yield.
There are about 150 film capacitor makers in mainland China, of which 80 percent are small and midsize operations, and trading companies. The first two supplier types churn out 2 million to 50 million units monthly, and their large counterparts more than 80 million units. Nantong Jianghai and Anhui Tongfeng are among the latter group. Dongguan Easy-Gather and Shenzhen Topmay each have an output of 5 million units a month, Shenzhen Shanrui 20 million and Shenzhen Shengtai 50 million.
Foreign-invested companies such as Japan's TDK and those from Taiwan make up the rest of the manufacturing pool.
Forty to 50 percent of the makers are based in Guangdong province, and the others in the provinces of Fujian, Anhui, Zhejiang and Jiangsu.
