High-Efficiency Robust Free-Standing Composited Phosphor Films with 2D and 3D Nanostructures for High-Power Remote White LEDs.

This study demonstrated that combined free-standing quasi-amorphous/micropattern (QA/MP) composited resin film-assisted phosphor films enhanced the mechanical robustness, luminous efficacy, color rendering index (CRI), and special R9 of high-power remote warm white light-emitting diodes (WLEDs). Introducing QA/MP nanostructures into phosphor film resulted in high efficiency of remote warm WLEDs with low phosphor thickness (approximately 25 μm) and reduced the correlated color temperature (CCT) from cold white light (approximately 5565 K) to warm white light (approximately 3178 K). The QA/MP composited phosphor films (CPFs) used for high-power remote WLEDs enhanced the CRI and special R9 and reduced the CCT. These results were attributed to that QA resin film reflected the blue light and re-emitted the added red emission. CIR (84), a natural warm white CCT (3178 K), and an acceptable luminous efficacy (102.5 lm/W) were achieved from the QA/MP CPFs of high-power remote WLEDs during operation at an input power of 10 W (current of 700 mA). The bending strength of QA/MP CPFs at approximately 112 N was significantly enhanced by 40% compared with that of flat CPFs. The QA/MP CPFs applied to high-power remote WLEDs exhibited good thermal and optical stability. QA/MP CPFs were also conducted to a reliability analysis (RA), in which temperature of 85 °C and relative humidity of 85% were applied for 3288 h. Lumen maintenance was degraded by 8% during RA test because the transmittance of trimethylolopropane ethoxylate triacrylate resins was degraded under high temperature. Overall, we implemented a reliable and inexpensive technology that can potentially reduce phosphor thickness, address the out-bin problems of defective WLEDs, and fabricate flat-panel lighting source with good lighting quality.