Fabrication of a Phosphor-in-Silica Glass Spectral Converter via Injection Molding for Stable and High-Power Broadband LEDs

The encapsulation of phosphor particles into a silica glass (PiSG) matrix leads to the formation of an efficient and chemically durable spectral converter, which is a promising candidate for the fabrication of stable and high-power phosphor-converted white light-emitting-diodes (pc-wLEDs). Here, high-throughput fabrication of transparent PiSG spectral converters based on Y 3 Al 5 O 12 :Ce 3+ , Mg 2 Al 4 Si 5 O 18 :Eu 2+ , and Y 3 Al 5 O 12 :Cr 3+ is demonstrated via injection molding followed by pressureless sintering. The as-fabricated PiSG exhibits broadband emission covering the visible and near-infrared (vis-NIR) spectral regions (i.e., 500–900 nm) with a high-luminescence efficiency (> 85%) and high-chemical and thermal stabilities, retaining more than 90% of its emission intensity at 200 °C. Consequently, high-power pc-vis-NIR-LEDs (10 W) are manufactured using the injection molded PiSG spectral converters, which showed excellent luminescence performance (i.e., luminous efficiency (LE) = 115 Im W −1 , correlated-color-temperature (CCT) = 4531 K, and color-rendering-index (R a ) = 90.1 at 50 mA and input power of 0.45 W). This work enables the fabrication of stable and high-power broadband LEDs with a low cost and outstanding optical properties, making the as-fabricated pc-vis-NIR-LEDs based on PiSG spectral-converter a favorable device for lighting and bioimaging applications.