Highly efficient large-area ultrathin phosphor-glass composites fabricated by tape-casting for super-bright LED lights

Abstract

Driven by the demand for super-bright LED lights for cars, buses, and trucks, highly efficient and large-area ultrathin phosphor-glass composites (PGC) with exceptional thermal dissipation capabilities were fabricated by a combined technique of tape-casting + low-temperature cofiring process. Two kinds of ultrathin (100 μm thick) PGC plates uniformly incorporated with YAG:Ce and CaAlSiN₃:Eu²⁺ phosphor particles and with a large size of 1044×45 mm were successfully prepared. At room temperature, photoluminescence quantum yields (PLQY) of 98.6% and 80% were achieved for the former and latter kinds of PGC glasses, respectively. Moreover, color tunable emissions were yielded in the ultrathin PGC by varying the weight ratio of different phosphors. Finally, light-emitting diodes (LEDs) encapsulated with different ultrathin PGC were demonstrated to exhibit outstanding luminous performance. When exposed to blue laser irradiation, the prepared PGC glasses demonstrated a heightened resistance to laser radiation. These unparalleled ultrathin PGC glasses could offer an unprecedented solution for the commercial applications in preparation of super bright car LED lights.