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WO 2016/138389 Al 1 September 2016 (01.09.2016) P O P C T (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization International Bureau (10) International Publication Number (43) International Publication Date WO 2016/138389 Al 1 September 2016 (01.09.2016) P O P C T (51) International Patent Classification: in, L.; 325 S. San Dimas Canyon Dr., Apartment #95, San H02N 11/00 (2006.01) Dimas, CA 91773 (US). DOTY, Benjamin, J.; 187 S. Marengo Ave., #2, Pasadena, CA 9 1101 (US). MOLINA, (21) International Application Number: Gabriel; 1200 E. California Blvd., Pasadena, CA 9 1125 PCT/US20 16/0 19786 (US). CORMARKOVIC, Velibor; 128 N. Oak Knoll (22) International Filing Date: Ave, Unit 108, Pasadena, CA 9 1101 (US). KEYAWA, 26 February 2016 (26.02.2016) Nicholas, R.; 11026 Baird Avenue, Porter Ranch, CA 91326 (US). KULCZYCKI, Eric, A.; 4607 Castle Rd., La (25) Filing Language: English Canada Flintridge, CA 9101 1 (US). PAIK, Jong-Ah; 210 (26) Publication Language: English S. Oak Knoll Ave #9, Pasadena, CA 9 1101 (US). FIR- DOSY, Samad; 2753 Harmony Place, La Crescenta, CA (30) Priority Data: 91214 (US). 62/121,084 26 February 2015 (26.02.2015) US (74) Agent: PECK, John, W.; KPPB LLP, 2400 E. Katella, (71) Applicant: CALIFORNIA INSTITUTE OF TECHNO¬ Suite 1050, Anaheim, CA 92806 (US). LOGY [US/US]; 1200 E. California Boulevard, M/C 6-32, Pasadena, CA 1125 (US). (81) Designated States (unless otherwise indicated, for every kind of national protection available): AE, AG, AL, AM, (72) Inventors: EWELL, Richard, C ; 1053 East Mendocino AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, Street, Altadena, CA 91001 (US). FLEURIAL, Jean-Pi¬ BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, erre; 1947 N. Roosevelt, Altadena, CA 91001 (US). PA- DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, TEL, Jagdishbhai, U.; 420 N. Milton Dr., San Gabriel, HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR, CA 91775 (US). NESMITH, Bill, J.; 6809 Estepa Dr, KZ, LA, LC, LK, LR, LS, LU, LY, MA, MD, ME, MG, Tujunga, CA 91042 (US). LI, Billy, Chun-Yip; 1341 MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, OM, Wakeforest Ave, Walnut, CA 91789 (US). SMITH, Kev¬ PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, SC, [Continued on nextpage] (54) Title: RADIOISOTOPE THERMOELECTRIC GENERATOR (57) Abstract: Thermoelectric generators (TEGs) and systems of such TEGs, and more particularly thermoelectric generators incorporating radiological heat sources (RTGs) capable of being utilized in inaccessible and confined spaces, and methods of producing such RTGs, are provided. The RTGs are configured to operate in high temperature, high pressure, and high vibration environments (e.g., within a drill string down-hole in a drilling environment) where the ambient operating temperatures of the RTGs may exceed -150° C, and the hydrostatic pressure of the environment within which the TEG is located may exceed 30,000 psi. w o 2016/138389 A i III II I I 11 I I lllll 111 I II III lllll lllll II lllll lllll 111 llll 11llll SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, IT, LT, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW. LU, LV, MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, (84) Designated States (unless otherwise indicated, for every GN, GQ, GW, KM, ML, MR, NE, SN, TD, TG). kind of regional protection available): ARIPO (BW, GH, GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, ST, SZ, Published: TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, — with international search report (Art. 21(3)) TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, RADIOISOTOPE THERMOELECTRIC GENERATOR STATEMENT REGARDING FEDERAL FUNDING [0001] The invention described herein was made in the performance of work under a NASA contract NNN12AA01C, and is subject to the provisions of Public Law 96-517 (35 USC 202) in which the Contractor has elected to retain title. CROSS-REFERENCE TO RELATED APPLICATIONS [0002] This application claims priority to U.S. Provisional App. No. 62/121,084, filed, February 26, 2015, the disclosure of which is incorporated herein by reference. FIELD OF THE INVENTION [0003] The present invention generally relates to radioisotope thermoelectric generators, and more particularly to miniaturized versions of such systems for providing in-situ power for space constrained applications. BACKGROUND [0004] Thermoelectric generators, or (TEGs) are solid state devices that convert heat (i.e., temperature differences) into electrical energy through a thermoelectric phenomenon called the Seebeck effect. In its most basic form a thermoelectric generator includes a circuit consisting of two dissimilar thermoelectric materials (i.e., an n-type (negatively charged) semiconductor and a p-type (positively charged) semiconductor) joined at their ends. A direct electric current flows in the circuit when there is a temperature gradient across the two materials. Generally, the current magnitude has a proportional relationship with the temperature difference (i.e., the more the temperature difference, the higher the current.) A radioisotope thermoelectric generator (RTG) is a TEG where the heat source is derived from the heat released by the decay of a suitable radiological material. [0005] Regardless of the heat source, there are many challenges in designing reliable TEG and RTG systems. For example, because RTGs and TEGs operate optimally in very high temperature gradients, the modules are subject to large thermal induced stresses and strains. RTGs and TEGs are also subject to mechanical fatigue caused by thermal cycling. As a result, achieving high efficiency in the system requires extensive engineering design in order to balance between the heat flow through the modules and maximizing the temperature gradient across them. The typical solution is to design a sophisticated heat exchange system. However, such systems add bulk and complexity to these systems. SUMMARY OF THE INVENTION [0006] Systems, methods and apparatus in accordance with embodiments of the invention implement miniaturized radioisotope thermoelectric systems. In embodiments, the mini-RTG systems may be implemented within a drill casing making them suitable for use in drilling applications as down-hole power sources. [0007] Some embodiments of the disclosure are directed to radioisotope thermoelectric generators including: • an enclosure having an inner wall defining an enclosure volume; • a heat source casing having an outer wall and defining an internal casing volume; • at least one mechanical linkage interconnected between the heat source casing and the enclosure, the at least one mechanical linkage securely suspending the heat source casing within the enclosure volume, isolated from the inner walls of the enclosure; • at least one radiological material disposed within the internal casing volume, the at least one radiological material emitting heat from the radioactive decay thereof such that the outer wall of the heat source casing is at a heated temperature; • at least one thermopile comprised of a plurality of elongated thermocouples each of the plurality of thermocouples being a pair of thermoelectric elements wherein one of the thermoelectric elements of each pair is formed of a p-type thermoelectric material and wherein one of the thermoelectric elements of each pair is formed of an n-type thermoelectric material, and wherein the adjacent ends of the thermoelectric elements of the elongated thermocouples are conductively interconnected into a circuit; • at least one electrically insulating element disposed on each of the opposing ends of the conductively interconnected thermocouples of each of the thermopiles, and wherein at least a first electrically insulating element is disposed on a first side of the thermopile and is mechanically engaged with the outer wall of the heat source casing such that the first side of the thermopile is thermally interconnected therewith, and wherein at least a second electrically insulating element is disposed on a second side of the thermopile and is mechanically engaged with the inner wall of the enclosure such that the second side of the thermopile is thermally interconnected therewith; • at least one conductive element electrically interconnecting the circuit of the at least one thermopile to an external circuit; and • wherein the temperature of the inner wall of the enclosure is at a temperature lower than the heated temperature of the outer wall of the heat source casing such that a direct current is established in the circuit of the at least one thermopile via the Seebeck effect. [0008] In other embodiments at least the first electrically insulating element is fixedly secured to the heat source casing, and wherein at least the second electrically insulating element is mechanically compliant and slidingly engaged with the inner wall of the enclosure. [0009] In still other embodiments the second electrically insulating element is one of either a spring or a carbon fiber pad. In many such embodiments the first electrically insulating element is fixedly attached to the heat source casing via brazing. [0010] In yet other embodiments the radioisotope thermoelectric generator further includes a thermal insulating material disposed between the outer wall of the heat source casing and the inner wall of the enclosure and filling the unoccupied portion of the enclosure volume. In some such embodiments the insulating material is aerogel that may include the use of a noble gas. [0011] In still yet other embodiments the radioisotope thermoelectric generator further includes a plurality of thermopiles conductively interconnected in series. [0012] In still yet other embodiments the radiological material is selected from the group consisting of plutonium-238, curium-244, strontium-90, polonium-210, promethium-147, caesium- 137, cerium- 144, ruthenium- 106, cobalt-60, curium-242, americium-241, thulium isotopes.
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