How to Make Meltdown-Proof Nuclear Fuel Pellets
This patent describes a method for making a new type of nuclear fuel called Dispersion Ceramic Micro-Encapsulated (DCM) fuel, which uses tiny, specially coated uranium particles embedded in a super-strong silicon carbide material to prevent meltdowns in nuclear reactors.
Original patent title: “Dispersion ceramic micro-encapsulated (DCM) nuclear fuel and related methods”
This patent describes a method for making a new type of nuclear fuel called Dispersion Ceramic Micro-Encapsulated (DCM) fuel, which uses tiny, specially coated uranium particles embedded in a super-strong silicon carbide material to prevent meltdowns in nuclear reactors. Granted to Ultra Safe Nuclear in 2019 with 20 claims and 12 forward citations, and it is expected to expire in 2037.
Coverage
What does this patent actually cover?
The patent outlines a method (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1) for manufacturing Dispersion Ceramic Micro-Encapsulated (DCM) nuclear fuel. This process involves creating at least two different sizes of 'tristructural-isotropic (TRISO) fuel particles.' Each TRISO particle contains a fuel kernel surrounded by four protective layers: a porous carbon buffer, an inner pyrolytic carbon layer, a ceramic layer, and an outer pyrolytic carbon layer. These TRISO particles are then mixed with a silicon carbide powder and sintered (heated and pressed) using a specific 'nano infiltration transient eutectic phase' to embed them within a dense silicon carbide matrix. This forms a solid fuel compact, or pellet, designed for enhanced safety. For example, Claim 6 details forming the fuel kernel by dissolving material in nitric acid, creating droplets, gelling, calcining, and then coating them in a chemical vapor deposition furnace (Claim 7).
The gap
What does this patent NOT cover?
- Does not cover nuclear fuel that uses only a single size of TRISO fuel particles, as ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1 specifies "two or more different sizes."
- Does not cover fuel compacts where TRISO particles are not dispersed and embedded inside a silicon carbide matrix, as required by ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1.
- Does not cover manufacturing methods that do not utilize a "nano infiltration transient eutectic phase" for sintering, as specified in ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1.
- Does not cover TRISO fuel particles that lack any of the four specified layers: porous carbon buffer, inner pyrolytic carbon, ceramic, and outer pyrolytic carbon (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1).
- Does not cover fuel compacts formed without pressing in a mold at a predetermined sintering pressure and temperature (ClaimclaimA numbered sentence at the end of a patent that legally defines what the inventor owns. The most important section.Read more → 1).
These exclusions are unique to PatentBrief — derived from the actual claim language, not patent-office boilerplate.
Key facts
What made this novel
The innovation lies in combining multiple, carefully sized TRISO fuel particles within a highly dense silicon carbide matrix, using a specialized sintering process. This creates a fuel pellet with exceptional structural integrity and multiple layers of containment, making it uniquely resistant to extreme conditions and preventing the release of radioactive materials even if the reactor core overheats.
The Patent Drawing
Schematic visualization of the patent's claim structure. Hand-drawn diagrams in progress for each landmark patent.
Where you've seen this
Real-world examples
Ultra Safe Nuclear Corporation's Fully Ceramic Micro-encapsulated (FCM) fuel
Advanced accident-tolerant nuclear fuels (ATF) for light water reactors
Next-generation nuclear reactor fuel designs
Why it matters
The bigger picture
This patent is significant because it describes a method for creating "meltdown-proof, accident-tolerant fuel" for existing light water reactors (LWRs). By replacing traditional uranium dioxide fuel with DCM fuel, the risk of radioactive material release during a severe accident is substantially reduced due to the multiple robust barriers around the fuel. This technology could enhance the safety of current nuclear power plants and potentially support the development of advanced reactor designs, addressing critical concerns about nuclear safety.
Filed
January 31, 2017
Granted
November 12, 2019
Market context
Who's building on this
Companies in this space
Ultra Safe Nuclear Corporation, the assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more → of this patent, is actively developing and commercializing advanced nuclear fuels, including their Fully Ceramic Micro-encapsulated (FCM) fuel, which directly aligns with the technology described here. Other companies and national laboratories involved in advanced nuclear reactor development are also researching and developing accident-tolerant fuels to enhance safety and performance.
Market impact
This patent contributes to the ongoing development of safer nuclear fuels, a critical factor for the future of nuclear energy. By offering a "meltdown-proof" alternative, it aims to address public safety concerns and could enable the broader adoption of new small modular reactors (SMRs) and the continued, safer operation of existing light water reactors. This technology seeks to mitigate the risk of catastrophic accidents, which has historically impacted the nuclear power industry's growth and public perception.
Claim 1 — Plain English
What this patent covers
The patent outlines a method (Claim 1) for manufacturing Dispersion Ceramic Micro-Encapsulated (DCM) nuclear fuel. This process involves creating at least two different sizes of 'tristructural-isotropic (TRISO) fuel particles.' Each TRISO particle contains a fuel kernel surrounded by four protective layers: a porous carbon buffer, an inner pyrolytic carbon layer, a ceramic layer, and an outer pyrolytic carbon layer. These TRISO particles are then mixed with a silicon carbide powder and sintered (heated and pressed) using a specific 'nano infiltration transient eutectic phase' to embed them within a dense silicon carbide matrix. This forms a solid fuel compact, or pellet, designed for enhanced safety. For example, Claim 6 details forming the fuel kernel by dissolving material in nitric acid, creating droplets, gelling, calcining, and then coating them in a chemical vapor deposition furnace (Claim 7).
The clever bit
The innovation lies in combining multiple, carefully sized TRISO fuel particles within a highly dense silicon carbide matrix, using a specialized sintering process. This creates a fuel pellet with exceptional structural integrity and multiple layers of containment, making it uniquely resistant to extreme conditions and preventing the release of radioactive materials even if the reactor core overheats.
What it does not cover
- Does not cover nuclear fuel that uses only a single size of TRISO fuel particles, as Claim 1 specifies "two or more different sizes."
- Does not cover fuel compacts where TRISO particles are not dispersed and embedded inside a silicon carbide matrix, as required by Claim 1.
- Does not cover manufacturing methods that do not utilize a "nano infiltration transient eutectic phase" for sintering, as specified in Claim 1.
- Does not cover TRISO fuel particles that lack any of the four specified layers: porous carbon buffer, inner pyrolytic carbon, ceramic, and outer pyrolytic carbon (Claim 1).
- Does not cover fuel compacts formed without pressing in a mold at a predetermined sintering pressure and temperature (Claim 1).
Patent timeline
Application submitted to the patent office
Application published, typically 18 months after filing
Patent officially issued
Patent enters public domain
PatentBrief Score
Impact Score
Moderate
Citation count
22/40
Moderately cited
Claim breadth
13/20
Broad claimsclaimsThe numbered statements at the end of a patent that legally define what the inventor owns.Read more →
Recency
10/20
Granted 5–10 years ago
Assignee scale
0/20
Independent or smaller assigneeassigneeThe entity that owns the patent — usually the inventor's employer or a company.Read more →
PatentBrief Impact Score — based on citation count, claim breadth, recency, and assignee scale. Not a legal assessment.
Heuristic Value Estimate
What this patent might be worth
$117K – $374K
Midpoint $234K · 10.3 yr remaining · industry ×1.5
Heuristic only — blends forward/backward citation counts, claim scope, time remaining, litigation history, and CPC-derived industry baseline. Real valuations need a professional appraisal.
Claim text not yet imported for this patent
The original legal language
Original claims
20 claims as filed with the patent office.
Concepts involved
Citations
Patent lineage
Cite this patent
Venneri, F. (2019). How to Make Meltdown-Proof Nuclear Fuel Pellets (U.S. Patent No. 10,475,543). U.S. Patent and Trademark Office. https://patentbrief.org/patent/us/10475543/dispersion-ceramic-micro-encapsulated-dcm-nuclear-fuel-and-related-methods
Auto-generated from the patent record. Double-check author order and the issue date against the official USPTO document before submitting.
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Common Questions
Frequently Asked Questions
What does How to Make Meltdown-Proof Nuclear Fuel Pellets cover?
This patent describes a method for making a new type of nuclear fuel called Dispersion Ceramic Micro-Encapsulated (DCM) fuel, which uses tiny, specially coated uranium particles embedded in a super-strong silicon carbide material to prevent meltdowns in nuclear reactors.
Who owns patent US 10475543?
Ultra Safe Nuclear owns this patent, granted in 2019.
When does this patent expire?
This patent is expected to expire on January 31, 2037, when the invention enters the public domain.
What is patent US 10475543 cited by?
This patent has been cited by 12 later patents that build on its ideas.
What problem does this patent solve?
This patent is significant because it describes a method for creating "meltdown-proof, accident-tolerant fuel" for existing light water reactors (LWRs). By replacing traditional uranium dioxide fuel with DCM fuel, the risk of radioactive material release during a severe accident is substantially reduced due to the multiple robust barriers around the fuel. This technology could enhance the safety of current nuclear power plants and potentially support the development of advanced reactor designs, addressing critical concerns about nuclear safety.
What does this patent NOT cover?
Does not cover nuclear fuel that uses only a single size of TRISO fuel particles, as Claim 1 specifies "two or more different sizes."
Patent monitoring