Laser-driven illumination has unique advantages in high-power applications. Taking advantage of the valuable experience of light-emitting diodes (LED) development, phosphor in silicone (PiS) is considered to be one of the most potential commercial phosphor converter solutions for laser-driven illumination. However, the thermal quenching of the PiS converter is a bottleneck problem. Herein, a boron nitride (BN)-coated copper foam strategy is introduced for the laser-driven illumination system. The phosphor/silicone is embedded in the designed BN/copper foam to form a phosphor in metal (PiM) converter. Copper foam serves as an internal connected heat transfer channel; the BN coating solves the light absorption problem of the copper foam effectively. Based on this PiM(BN/copper foam) design, the heat dissipation is effectively improved. Under high-power laser excitation (8.13 W), the PiS converter cannot reach thermal equilibrium, and therefore the temperature increases sharply up to 660 °C. In comparison, the thermal performance of an optimized PiM(BN/copper foam) converter is able to maintain excellent stability, where the maximum temperature is only 166.5 °C. The proposed PiM strategy has a maximum temperature that is 493.5 °C lower than that of the reference PiS solution. Due to the superior thermal management, the luminous efficiency of the illumination system is constantly stable at 254 lm/W, though with less phosphor mass; and the related color temperature is about 6000 K all the time. This provides a practical and feasible heat-dissipation solution for high-power laser-driven illumination.
Keywords: boron nitride; copper foam; heat dissipation; laser-driven illumination; optical stability; phosphor in metal (PiM).