this laser "bulb" cant be used in a halogen assembly, because the specs that the manufacturer claims the headlamp assembly meets, specifies a bulb type and just because this has the right base and emitter position, it isnt compliant because it doesnt torture a bit of tungsten in a glass tube?
Legally, that's the case. Technically, the reasons are more numerous and complex. The main optical one is discussed above. There are others, too. Let's suppose we can wiggle our nose like Samantha Stevens on "Bewitched" (see
here if you aren't familiar) and move this idea directly to the actual-product stage. Presto, we have a laser-and-phosphor-tube "bulb" designed to go in place of an HB4 (9006) halogen bulb.
It is an established principle of the governing laws and regulations that fundamentally different types of light source cannot be legal in headlamps even if they're designed to be physically and geometrically compatible, and that headlamps and bulbs be designed to prevent installation or acceptance of any but the intended bulb -- some of those prevention features are more robust than others, some are easily defeated, but that's beside the point. We have this light source that we have designed to put out exactly the same amount of light, its emitting surface is the same size and shape as the HB4 filament and it's positioned the same. But glowing phosphor tubes aren't the same as glowing filaments, and can't be made to be the same. The luminance distribution is different, for example. There are
going to be fundamental differences in the output. Since 1986, there have been many thousands of different headlamps designed to use the HB4 bulb. What proportion of them do we have to test and get beam photometry results that are practically identical (or let's make it easier and say results that are legally acceptable) in order to declare this laser bulb a drop-in? If the answer isn't 100%, it's damn near, because there are real and serious liability issues involved.
Now let's assume we test (say) 2500 different HB4 headlamps, including a large number of all kinds of different optical technologies -- projectors, parabolic reflectors, compound-optic reflectors of all types, with bulb shields, without bulb shields, round, rectangular, large, small, VOL, VOR, the whole gamut -- and this laser bulb sailed through the beam tests each and every time, so even the most hardnosed NHTSA engineer had to admit that optically and photometrically, for all intents and purposes this thing is a drop-in. Then does the regulation change? No, because all those headlamps that stay free of snow and ice buildup in wintertime conditions with a halogen bulb now frost up quickly and badly when equipped with this new light source. Light comes out the front of the laser diode...and heat gets pulled off the back. The driver can't see any more when he needs his headlamps the most, which is a long way of saying the headlamps have been rendered inoperative, which is a direct and large violation of federal law in place for very good reasons.
And speaking of the back: take another look at that rendering of this laser bulb. Notice how much longer and more massive it is behind the seating plane than the bulb it replaces: about triple not counting whatever is obviously intended to screw onto what's shown here as the rearmost point of the bulb. No problem if we're putting it in a self-contained, sealed headlamp with a sturdy, robust bulb seat, in a large vehicle with ample space behind the headlamps. But many vehicles have almost no space behind the headlamps, and even if they did, that's not the only kind of headlamp out there, not by a long shot. There are also many headlamps that have reflectors and internal optics that are open to the elements unless the bulb access panels are firmly installed. The bulb access panels go behind the bulbs, and often there's not much clearance between the rear of the (intended) bulb and the access panel. Oops...guess we'll have to leave the bulb access panel off once we install this laser bulb. Now our headlamps quickly fill up with water and dirt and errant spiders. And what of the many headlamps that have bulb holders just adequate to hold a small, low-mass halogen bulb in position? Suddenly we're throwing a big lever against these bulb holders. The back of the bulb will sag downward (and jump up and down as we go over road bumps). Not only is our beam pattern shot to hell, not only is it bouncing around on the road, but now we've got another access path for water and dirt.
Shall I go on? (I can...I could talk about the reason why the Philips "here's a list of vehicles we tried these on and found OK results" strategy, while weakly arguable in the case of stop/reverse/tail/turn signal bulbs, is not even arguably valid for headlight lamps because of differences in how they're regulated...)
Does that then mean that the only way this "bulb" will be ok for use is in an appropriately designed headlamp assembly (which could jist as easily be designed for LED, or HID, or Halogen instead)
Yes. If the idea makes it to a commercial stage, it might be suitable for creating new light sources not intended for retrofitting in place of old light sources.