The development of ultra-high-brightness laser-driven phosphor-converted light sources is significantly challenged by high-power-density laser irradiation, primarily due to the thermal quenching effect induced by excessive heat accumulation in the phosphor. Conventional approaches aimed at improving the heat dissipation performance of phosphor converters, such as phosphor-in-glass (PiG) and ceramic plates, often requiring the use of attached substrates and thermal interface materials (TIMs), tend to be relatively complex and susceptible to delamination at the interfaces. Here, we proposed a fast, low-cost and TIM-free fabrication of monolithic ceramic-glass modules with integrated top YAG:Ce phosphor layer and bottom alumina layer (as substrate). In the fabricated modules, tight interfacial bonding without cracks was achieved between the phosphor layer and the alumina layer, which is attributed to their matched thermal expansion coefficients as well as a shared glass component. The effects of the phosphor layer’s thickness and glass ratio were examined with respect to the absorption of incident light and the subsequent heat dissipation, as the luminous efficacy is directly governed by the converter’s thermal management. Also, the effects of thickness and glass ratio of phosphor layer on fluorescent-emitting spot expansion (compared to laser spot) and luminous exitance were also investigated. This study not only provides a novel design of a phosphor module for laser lighting but also identifies the critical parameters for enhancing its photo-thermal performance to meet the demands of higher-power laser lighting applications.
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