Techniques for incorporating sensors into apparatuses and systems

Patent metadata

Field	Value
Publication number	US-12148538-B2
Application number	US-202017089922-A
Country	US
Kind code	B2
Filing date	Nov 5, 2020
Priority date	Nov 5, 2019
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

Methods of placing sensors in structures may involve placing first particles including a first material of the structure on or above a support surface. Second particles including a second, different material may be dispersed among the first particles at least within a transition region of the structure proximate to a location where a sensor is to be supported by the structure. A sensor may be placed in the location. The first particles of the first material may be fused to one another and to the second particles of the second material to form the structure with the sensor supported by the structure.

First claim

What is claimed is:

1. A method of placing a sensor in a structure, comprising:
placing first particles comprising a first material of a structure in a first region and in a transition region proximate to the first region on or above a support surface, the transition region proximate to a location where a sensor is to be supported by the structure;
dispersing second particles comprising a second, different material among the first particles at least within the transition region, such that a value of at least one material property within the transition region, once fused, is intermediate a first value of the at least one material property within the first region and a fourth value of the at least one material property of the sensor, the second particles exhibiting a coefficient of thermal expansion between a coefficient of thermal expansion of the first particles and a coefficient of thermal expansion of a material of the sensor;
placing the sensor in the location; and
fusing the first particles of the first material to one another and to the second particles of the second material to form the structure with the sensor supported by the structure.

2. The method of claim 1 , wherein placing the sensor in the location comprises forming the sensor in situ in the location by placing third particles of a material of the sensor in the location and fusing the third particles of the material of the sensor with one another to form the sensor supported by the structure.

3. The method of claim 2 , further comprising placing the third particles within a space at least partially defined by fourth particles of a fourth material, the fourth particles interposed between at least some of the third particles and at least some of the first and second particles, and fusing the fourth particles to form a housing comprising a protective material interposed between at least a portion of the sensor and the structure.

4. The method of claim 1 , wherein placing the sensor in the location comprises placing a preformed sensor in the location.

5. The method of claim 4 , further comprising placing the preformed sensor in a housing comprising a protective material, the housing interposed between the sensor and the first and second particles when the sensor is placed in the location.

6. The method of claim 1 , wherein placing the first particles comprising the first material comprises placing first particles comprising a core comprising the first material and a casing comprising the second material or a material of the sensor.

7. The method of claim 1 , further comprising dispersing other particles of another material configured to absorb fission products or corrosive products among the first particles of the structure.

8. The method of claim 1 , wherein dispersing the second particles among the first particles comprises forming a gradient in the at least one material property, a value of the at least one material property falling between values for corresponding material properties of the first material and a material of the sensor, utilizing a distribution of the second material within the first material.

9. The method of claim 1 , wherein dispersing the second particles among the first particles comprises placing alternating layers of the second particles and the first particles within the transition region.

10. The method of claim 1 , further comprising mixing the first particles and the second particles, increasing surface roughness, before fusing the first particles of the first material to one another and to the second particles of the second material to form the structure with the sensor supported by the structure.

11. The method of claim 10 , wherein mixing comprises vibrating, exposing to flowing fluid, or exposing to flowing electrical current.

12. A method of placing a sensor in a structure, comprising:
placing first particles comprising a first material of a structure in a first region and in a transition region proximate to the first region on or above a support surface, the transition region proximate to a location where a sensor is to be supported by the structure;
dispersing second particles comprising a second, different material among the first particles at least within the transition region of the structure proximate to a location where a sensor is to be supported by the structure, such that a value of at least one material property within the transition region, once fused, is intermediate a first value of the at least one material property within the first region and a fourth value of the at least one material property of the sensor the second particles exhibiting a coefficient of thermal expansion between a coefficient of thermal expansion of the first particles and a coefficient of thermal expansion of a material of the sensor;
mixing the first particles and the second particles to increase surface roughness of the first particles and the second particles;
placing the sensor in the location; and
fusing the first particles of the first material to one another and to the second particles of the second material after mixing the first particles and the second particles to form the structure with the sensor supported by the structure.

13. The method of claim 12 , wherein placing the sensor in the location comprises forming the sensor in situ in the location by placing third particles of a material of the sensor in the location and fusing the third particles of the material of the sensor with one another to form the sensor supported by the structure.

14. The method of claim 12 , wherein placing the sensor in the location comprises placing a preformed sensor in the location.

15. The method of claim 14 , further comprising placing the preformed sensor in a housing comprising a protective material, the housing interposed between the sensor and the first and second particles when the sensor is placed in the location.

16. The method of claim 15 , wherein a material of the housing comprises at least one of depleted uranium, depleted thorium, barium sulfate, a metal oxide, steel, aluminum, aluminum alloy, copper, copper alloy, chrome, chrome alloy, lead, or lead alloy.

17. The method of claim 12 , further comprising leaving a portion of the first material and a portion of the sensor exposed after fusing the first particles to one another and to the second particles.

18. The method of claim 12 , wherein placing the first particles on or above the support surface comprises placing the first particles on or above a platform comprising the support surface utilizing a 3D-printer.

19. The method of claim 12 , wherein fusing the first particles to one another and to the second particles comprises exposing the first particles and the second particles to heat to sinter the first particles to one another and to the second particles.

Assignees

• Battelle Energy Alliance Llc

Inventors

• Van Rooyen Isabella J
• Sabharwall Piyush

Classifications

• H10W40/47

  by flowing liquids, e.g. forced water cooling · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• G21C17/112

  Measuring temperature · CPC title

• F28D1/02

  with heat-exchange conduits immersed in the body of fluid · CPC title