Modular Beryllium Component for Fusion Reactor Vacuum Chamber
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Solution Overview
Problem
Current components for thermonuclear fusion reactors face challenges in managing complex geometries, high manufacturing costs, assembly time, and risk of defects, particularly due to their single-piece design and lack of modular structures capable of withstanding high heat fluxes and mechanical stresses.
Innovation Solution
A component comprising a multiplicity of elementary elements assembled by diffusion welding, with at least one layer of beryllium, allowing for variable geometry and improved resistance to thermal and mechanical stresses, and a method involving pre-assembly and finalization steps to reduce assembly time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-piece component design is used, then the component can withstand high heat fluxes and mechanical stresses, but the manufacturing cost increases and assembly time increases
Solution Approach 1:
The component is divided into multiple modular sub-components that can be manufactured separately and then assembled together. Each module can be produced independently using standardized processes, reducing manufacturing complexity and cost while maintaining the overall structural integrity and thermomechanical performance through controlled assembly joints.
2Manufacturing precision
If custom-made components are manufactured to reproduce complex reactor geometry, then the geometric precision is improved, but the manufacturing cost increases and chain production becomes difficult
Solution Approach 1:
The complex geometry is broken down into standardized modular units that can be manufactured using repetitive production processes. Each module follows standardized design specifications, enabling chain production while the overall complex geometry is achieved through the arrangement and assembly of these standardized modules.
Solution Approach 2:
The design uses standardized parameters and dimensions for modular components that can be produced efficiently through chain manufacturing. By standardizing key geometric parameters while allowing flexibility in module configuration, the system achieves both manufacturing efficiency and geometric precision for complex reactor geometries.
3Strength
If a single-piece component is manufactured, then the structural integrity is maintained, but the risk of defects affects the entire component leading to higher scrap costs
Solution Approach 1:
The component is segmented into multiple independent modules connected by controlled joints. This segmentation allows defective modules to be identified and replaced individually without scrapping the entire component, significantly reducing scrap costs while maintaining structural integrity through the modular assembly design.
Solution Approach 2:
The modular design inherently provides a cushioning effect against defects by isolating potential failure points within individual modules. A defect in one module does not propagate to other modules, and the modular structure allows for easy replacement of defective units, preventing total component failure.
4Ease of manufacture
If elementary elements are assembled on a large support, then the assembly is simplified, but additional manufacturing costs are incurred and geometry defects cannot be managed
Solution Approach 1:
Instead of assembling elementary elements on a single large support, the design segments the structure into multiple modular units that are self-supported or minimally supported. This eliminates the need for large supporting structures while maintaining assembly simplicity through standardized module interfaces and connection procedures.
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
The solution enables the production of reliable, cost-effective components that can withstand high heat fluxes and mechanical stresses, simplifying the assembly process and reducing the risk of defects, while maintaining precise thermomechanical properties.
Implementation Method 1
assembled by diffusion welding
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a component of a large structure, in particular a thermonuclear fusion reactor, intended for being subjected to a multiplicity of thermal flows and/or a stream of high-energy particles which can reach at least 1 MW/m2 and for withstanding a multiplicity of mechanical and/or thermal stresses. The invention also relates to a reliable and inexpensive method for assembling said component. Said component is provided with a stack comprising a multiplicity of layers of materials including at least one layer of beryllium and is mainly made up of an assembly of elementary elements which are smaller than 1/100 of the size of said component, placed side by side and assembled according to an atomic diffusion welding method. Each elementary element is provided with a stack comprising a multiplicity of layers (3) of materials including at least one layer of beryllium (2). The component is intended for covering the vacuum chamber of a reactor, in particular a thermonuclear fusion reactor.