Power Electronic Converter on Bio-Based Substrate: Design, Characterization, Aging and Disassembly

To mitigate the environmental impact of e-waste in power electronics, this paper introduces a bio-based insulated metal substrate (B2IMS) consisting of polylactic acid (PLA) deposited on a metal plate. The proposed substrate addresses two major limitations of PLA-based substrates for power converters: it remains effective under cyclic operating temperatures exceeding 100°C, and it is compatible with environmentally friendly SnAgCu solder, which requires a reflow temperature of 249°C. The paper describes the fabrication of a 35 W buck converter using the B2IMS and evaluates its performance under repetitive operating temperatures above 100°C. Despite the low glass transition temperature of PLA, the converter demonstrates stable operation during active power cycling. Finally, PLA hydrolysis is used for converter disassembly, thereby optimizing recycling selectivity and maximizing material valorization potential. These results represent a critical step toward the deployment of more environmentally sustainable power converters.