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

Abstract 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.