Beta-Voltaic Nuclear Battery Manufacturing via Swaged Casing

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Solution Overview

Problem

Radioisotope Thermal Generators (RTGs) face challenges in manufacturing with Plutonium-238, including high radiation shielding requirements due to beta emissions from alternative isotopes and limited power density, necessitating new methods for generating electrical energy directly from beta radiation and reducing radiation exposure.

Innovation Solution

The method involves creating a nuclear battery with a radiation source layer emitting beta radiation, using a casing layer to inhibit beta radiation traversal and generate a voltage potential, and incorporating a radiation shielding layer to minimize gamma radiation, allowing for direct electrical energy production and reduced shielding needs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If alternative beta-emitting isotopes are used in RTGs, then power density is improved, but radiation shielding requirements worsen due to gamma radiation production

Engineering Contradiction:

Improvepower densityVSAvoidgamma radiation

Core Design Contradiction:

PowerVSObject-affected harmful factors

Solution Approach 1:

The patent applies this principle by using the beta radiation that would normally be harmful to directly generate electrical energy through beta-voltaic conversion. The beta-emitting isotopes (such as Strontium-90, Zirconium-89, or Yttrium-90) are coupled with semiconductor detectors that convert beta particle energy directly into electricity, transforming the harmful radiation into a useful power source while reducing the need for extensive gamma shielding

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If Plutonium-238 is used in RTGs, then radiation shielding needs are minimized, but manufacturing challenges worsen

Engineering Contradiction:

Improveradiation shielding needsVSAvoidmanufacturing challenges

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent employs this principle by utilizing beta-emitting isotopes with shorter half-lives (ranging from days to years) that are more readily available and easier to manufacture with compared to Plutonium-238. Examples include Strontium-90 (29 years), Zirconium-89 (78.4 hours), and Yttrium-90 (64 hours). These isotopes can be produced in nuclear reactors or cyclotrons and incorporated into semiconductor devices using existing manufacturing techniques, avoiding the complex safeguards and handling requirements associated with plutonium

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Use of energy by moving object

If thermocouples are used to convert heat to electricity in RTGs, then electrical energy is generated, but power density is limited

Engineering Contradiction:

Improveelectrical energy generationVSAvoidpower density

Core Design Contradiction:

Use of energy by moving objectVSPower

Solution Approach 1:

The patent replaces the thermal-mechanical conversion system (thermocouples converting heat to electricity) with a direct particle-to-electricity conversion system. Beta-voltaic devices use semiconductor detectors where incident beta particles directly generate electron-hole pairs that are collected as electrical current, eliminating the inefficient thermal intermediate step and achieving significantly higher power density

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach enables the production of nuclear batteries that can generate electrical energy from beta radiation emissions without thermal conversion, increasing power density and reducing radiation exposure, while minimizing the need for large radiation shielding layers.

Implementation Method 1

a radiation source layer emitting beta radiation

Methodology Applied

Scientific EffectBeta radiation emission: Radioactive Decay

Implementation Method 2

generate electrical energy from beta radiation emissions without thermal conversion

Methodology Applied

Scientific EffectBeta-voltaic effect: Betavoltaics

Implementation Method 3

using a casing layer to inhibit beta radiation traversal and generate a voltage potential

Methodology Applied

Scientific EffectBeta radiation absorption: Absorption (EM radiation)

Implementation Method 4

incorporating a radiation shielding layer to minimize gamma radiation

Methodology Applied

Scientific EffectGamma radiation shielding: Absorption (EM radiation)

Data Source

PatentUS20250006389A1Methods of manufacture for nuclear batteries

Publication Date: 2025.01.02 WESTINGHOUSE ELECTRIC CORP

AI summary

Methods of manufacture for nuclear batteries are provided. The method comprises inserting a radiation source material into a cavity defined within a first component to form a radiation source layer. The first component comprises a first electrical insulator layer defining the cavity and a first casing layer disposed over the first electrical insulator layer. The method comprises contacting the first casing layer with a second casing layer of a second component to form an assembly. The second component comprises a second electrical insulator layer and the second casing layer disposed in contact with the second electrical insulator layer. The method comprises swaging the assembly to form the nuclear battery.