CaAlSiN3:Eu/glass composite film in reflective configuration: A thermally robust and efficient red-emitting color converter with high saturation threshold for high-power high color rendering laser lighting

To achieve high color rendering and proper color temperature, a red color converter is essential for phosphor-converted white lighting devices. CaAlSiN3:Eu2+ (CASN) is a highly suitable red phosphor for white light-emitting diodes. However, it can be hardly used in high-power laser lighting due to poor thermal/chemical performance of the phosphor/silicone resin mixture. A series of all-inorganic CASN-based phosphors (e.g., composite ceramic and phosphor-in-glass) were developed to avoid the use of resin. However, new challenges emerged: none of them showed sufficient luminous efficacy (i.e., >50 lm/W) and adequate saturation-threshold (i.e., >30 W or 10 W/mm2). Here, we report a facile fabrication of CASN/glass composite films using a simple and efficient blade-coating method. Upon 450 nm excitation, the resultant composite film presents a high internal quantum efficiency of ~83%, comparable to that of pristine CASN powder (~90%). When irradiated with a blue laser, the composite film shows a record high luminous efficacy of 82 lm/W. Furthermore, its saturation threshold was investigated in high power and high power density mode, respectively. When measured in high power mode, it shows a high saturation threshold over 29.7 W (1.75 W/mm2), thus achieving a high luminous flux of 1576 lm; when measured in high power density mode, it shows a saturation threshold of ~10.2 W/mm2 (1.13 W). With abovementioned excellent properties, the CASN/glass composite film has great potential for use in high-power and high color rendering laser lighting.