Systems, methods, and apparatus for providing low energy defrost and heating of multiple surfaces

Abstract

Systems, methods, and devices are provided for detecting and removing frozen build-up from a plurality of surfaces. The system comprises: a plurality of conductive elements connected to the plurality of surfaces; a power supply unit conductively connected to each of the plurality of conductive elements, the power supply unit configured to heat each of the plurality of conductive elements; and a controller unit connected to the power supply unit, the controller unit configured to activate the power supply unit for selectively heating each conductive element of the plurality of conductive elements. The system also includes an automatic activation based on detection of an ambient condition on each of the plurality of conductive elements, where the ambient condition includes an ice, frost, fog, moisture, or temperature threshold.

Description

Technical Field

[0001] The following generally relates to systems, methods, and devices for temperature control for surface de-icing and defogging, and more particularly, to systems, methods, and devices for low-energy defrosting and heating of multiple surfaces. Background Art

[0002] Various methods and systems are used to provide electro-thermal energy for surface heating, defrosting, de-icing, and defogging for surfaces such as windshields or other surfaces of a vehicle, as well as refrigeration equipment such as coils. Vehicles can include automobiles, electric vehicles, locomotives, airplanes, buses, and heavy goods vehicles.

[0003] In these systems and methods, the surface is typically equipped with built-in heating elements made by means of transparent or opaque conductive coatings. When an electric current is applied, these coatings are activated and generate heat. Without limitation to coatings, heating features can also be constructed using other conductive resources (such as fine wires). The integration of the conductive coating into the vehicle's own electrical infrastructure is achieved by means of busbars. The distribution and management of the current to these busbars and heating components are supervised by switches or dedicated processing units.

[0004] Electro-thermal surface defrosting and defogging systems operate based on the principle of resistive heating, which is achieved through conductive coatings or films placed on various surfaces such as the windshield and side mirrors of a vehicle or refrigerator coils. The inherent resistivity of the conductive coating or film ensures that when an electric current is applied to the conductive coating, the resistance of the coating causes resistive heating, which is transferred to the surface. Common materials used in conductive coatings include fluorine-doped tin oxide (FTO) and indium tin oxide (ITO) to elements such as carbon nanotubes and silver, each material being selected for its unique resistance and conduction characteristics.

[0005] Due to the inherent characteristics of resistive heating, a large amount of current is required to generate sufficient heat to defrost the surface. This conversion of electrical energy may not be efficient, and some energy may inevitably be lost. In addition, under certain local or environmental conditions, especially during extremely cold or high humidity periods, the defrosting system may need to operate continuously or frequently. This continuous use results in continuous consumption of the power source.

[0006] In a vehicle, the use of an electric defrosting system for the windshield and other windows may strain the vehicle's battery and alternator, especially if other high-consumption systems (such as heating, air conditioning, or entertainment systems) are also in use. This is even more evident in electric vehicles where battery life and range are crucial. To ensure safety, especially in a vehicle, it is crucial that the defrosting system works quickly. However, rapid heating uses more power, thus creating a trade-off between safety and efficiency.

[0007] During refrigeration, where the defrost cycle is crucial for maintaining efficiency and preventing icing, conventional defrost cycles can result in significant energy usage, thereby increasing operating costs and reducing the efficiency of the refrigeration system. Additionally, in some cases, the surrounding insulation or the design of the defrost system is not optimized, leading to heat loss, and as a result, the system draws more electricity to compensate.

[0008] Given the challenges of climate change, the industry and end-users tend to reduce energy consumption and adopt methodologies for enhanced energy efficiency. According to the International Institute of Refrigeration, the refrigeration process accounts for approximately 17% of global energy use, with defrost operations consuming approximately one-quarter (25%) of this designated portion.

[0009] In electric vehicles, including both cars and trucks, the process of defrosting the windshield requires significant energy usage, typically exceeding 4 kWh for a single defrost operation, especially when the range of the electric vehicle (EV) is inherently limited under cold conditions. The primary energy source for the defrosting and defogging functions in such EVs mainly originates from the vehicle's high-voltage battery pack. This battery pack also simultaneously serves as the main power source for the electric motor system, which affects the vehicle's operating range. Thus, any power allocation from the battery for defrosting and defogging operations inherently reduces the available driving range. Geotab TM Empirical tests conducted on a fleet of electric vehicles revealed that at temperatures approaching -20°C, the actual vehicle range decreased by 41% compared to the declared range, which was attributed to cabin thermal management, including defrosting and defogging. The implications from this analysis highlighted that for every 10°C decrease in ambient temperature from 24°C, the actual driving range of an EV decreases by approximately 20%.

[0010] It is noteworthy that in electric vehicles, in addition to the windshield, there is a need for surface heating across multiple components. This includes side windows, roof glass, rear windows, ADAS surfaces (Advanced Driver Assistance Systems, such as cameras, LiDAR), LED headlights, and external heat exchangers used with heat pump systems. Similar to the front windshield, side windows, moonroofs / sunroofs, and rear windows also use defrosting and defogging in cold weather to improve surrounding visibility. The front side windows are typically heated by hot air from the HVAC system via side ducts. Due mainly to the high energy consumption characteristics of existing technologies, contemporary defrost methodologies require a single solution application or a set of equipment for each individual surface.

[0011] In addition, in electric vehicles, regenerative braking provides an efficient way to capture kinetic energy and return energy to the battery. However, the brake calipers are used less frequently, and at cold temperatures, the brake calipers can freeze, where the ice renders the braking system inoperable. Accordingly, a heated braking system is also used as a safety precaution to ensure that the brakes operate properly in an EV, especially in cold weather.

[0012] In addition, as heat pumps become increasingly common for heating electric vehicles in colder climates, they typically utilize an outdoor heat exchanger (OHX) to extract heat from the ambient environment into the refrigerant. However, starting at just above the freezing point, such as +2°C and colder, the OHX begins to gradually accumulate frost on its fins and tubes. This frost accumulation impedes air flow and reduces the efficiency of the heat exchanger. Current solutions for defrosting the OHX involve energy-intensive defrost cycles that heat the coolant and generate heat, thereby allowing the entire OHX to be heated and the frost to be removed.

[0013] Similarly, multiple surfaces of an aircraft can use surface heating for defrosting and demisting, such as wings, windshields, tails, and horizontal stabilizers.

[0014] Multiple surfaces can also use heating in refrigeration systems. In large refrigeration equipment, various heat exchangers or evaporator coils can be integrated into the refrigeration system. For example, large cold storage facilities or commercial refrigerators / freezers typically employ many heat exchangers operating simultaneously to cover a vast space. Each individual evaporator heat exchanger is prone to frost accumulation and requires a significant amount of energy for defrosting.

[0015] Electric defrosting and demisting systems, especially when used across various surfaces, can draw a substantial amount of electricity. This can strain the energy source, leading to faster depletion of the battery in an electric vehicle. Additionally, managing and controlling multiple electric heating elements increases the complexity of the system, which can introduce potential points of failure.

[0016] Accordingly, there is a need for systems, methods, and devices that overcome one or more of the disadvantages associated with existing surface de-icing systems, particularly for providing low-energy defrosting and heating to multiple surfaces. SUMMARY OF THE INVENTION

[0017] A system for temperature control is provided, including detecting and removing frozen accumulations and defogging from multiple surfaces. The system includes a plurality of conductive elements connected to the multiple surfaces; a power supply unit conductively connected to each of the plurality of conductive elements, the power supply unit being configured to heat each of the plurality of conductive elements; and a controller unit connected to the power supply unit, the controller unit being configured to activate the power supply unit for selectively heating each of the plurality of conductive elements, wherein the plurality of conductive elements are controlled by a single controller unit for low-energy defrosting and defogging.

[0018] In one embodiment, the plurality of conductive elements include a plurality of material properties, the plurality of material properties including size, constituent material, conductivity, resistance, thermal coefficient, and structural dimensions.

[0019] In one embodiment, the controller unit is automatically activated based on detection of environmental conditions on each of the plurality of conductive elements, wherein the environmental conditions include at least one of the following: ice, frost, fog, moisture, relative humidity, and temperature threshold.

[0020] In one embodiment, the system further includes a power queue unit configured to identify the selective heating of each of the plurality of conductive elements based on the plurality of material properties and the environmental conditions of each of the plurality of conductive elements.

[0021] In one embodiment, the plurality of conductive elements are connected to a plurality of corresponding sensors to detect the environmental conditions of each of the plurality of conductive elements.

[0022] In one embodiment, the controller unit is connected to a sensor unit, wherein the sensor unit is configured to collect the detected environmental conditions from the plurality of corresponding sensors.

[0023] In one embodiment, the power supply unit includes a plurality of power sources corresponding to each of the plurality of conductive elements.

[0024] A method for detecting and removing frozen accumulations from multiple surfaces is provided. The method includes: sending sensor data from a plurality of conductive elements to a power supply unit; determining, by a power matrix, heating elements in the power matrix that need to be activated and determining the amount of energy required for the heating elements, wherein the heating elements are connected to corresponding conductive elements designated for heating; receiving, by a controller, a start signal to activate a low-energy multi-surface heating system, wherein the plurality of conductive elements are connected to multiple surfaces and the power supply unit is conductively connected to each of the plurality of conductive elements; determining, by a power queue, power management and distribution between the plurality of conductive elements designated for heating and a sequence for supplying power to the heating elements for achieving optimal time utilization and rapid de-icing and defrosting; and activating a power converter based on the power queue, wherein the power queue is configured to activate power delivery to the conductive elements designated for heating.

[0025] In one embodiment, the plurality of conductive elements include a plurality of material properties for adjusting resistance according to the surface, and the plurality of material properties include size, constituent material, conductivity, resistance, thermal coefficient, and structural dimensions.

[0026] In one embodiment, the power supply unit is automatically activated based on detection of environmental conditions on each of the plurality of conductive elements, wherein the environmental conditions include at least one of the following: ice, frost, fog, moisture, relative humidity, and temperature threshold.

[0027] In one embodiment, the method further includes identifying the selective heating of each of the plurality of conductive elements based on the plurality of material properties and the environmental conditions of each of the plurality of conductive elements.

[0028] In one embodiment, the plurality of conductive elements are connected to a plurality of corresponding sensors to detect the environmental conditions of each of the plurality of conductive elements.

[0029] In one embodiment, the power supply unit is connected to a sensor unit, wherein the sensor unit is configured to collect the detected environmental conditions from the plurality of corresponding sensors.

[0030] In one embodiment, the power supply unit includes a plurality of power sources corresponding to each of the plurality of conductive elements.

[0031] A device for detecting and removing frozen accumulations from multiple surfaces is provided. The device includes:

[0032] A processing module configured to activate a low - energy multi - surface heating function upon receiving a start signal, wherein a plurality of conductive elements are connected to a plurality of surfaces, and a power supply unit is conductively connected to each of the plurality of conductive elements; a power matrix module configured to manage a power matrix and determine which heating elements in the matrix need to be activated, wherein the power matrix includes conductive elements designated for heating; a sensor data collection module configured to receive sensor data sent from the plurality of conductive elements to the power supply unit; a power queue module configured to determine a power queue to manage power distribution among the conductive elements designated for heating; and a power converter module configured to activate a power converter based on the power queue, wherein the power queue is configured to activate power delivery to the conductive elements designated for heating.

[0033] In one embodiment, the plurality of conductive elements include a plurality of material properties, the plurality of material properties including size, constituent material, conductivity, resistance, thermal coefficient, and structural dimensions.

[0034] In one embodiment, the device is automatically activated based on detection of environmental conditions on each of the plurality of conductive elements, wherein the environmental conditions include at least one of the following: ice, frost, fog, moisture, relative humidity, and a temperature threshold.

[0035] In one embodiment, the plurality of conductive elements are connected to a plurality of corresponding sensors to detect environmental conditions on each of the plurality of conductive elements.

[0036] In one embodiment, the sensor data collection module is connected to a sensor unit, wherein the sensor unit is configured to collect the detected environmental conditions from the plurality of corresponding sensors.

[0037] In one embodiment, the power converter module is connected to a plurality of power sources corresponding to each of the plurality of conductive elements.

[0038] Upon reviewing the following description of some exemplary embodiments, other aspects and features will become apparent to those of ordinary skill in the art. BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The accompanying drawings included herein are used to illustrate various examples of the systems, methods, and devices of this specification. In the drawings:

[0040] Figure 1 A block diagram illustrating a system for de - icing and defogging an exposed surface is shown.

[0041] Figure 2 FIG. 1 shows a schematic diagram of an electronic device 200 according to an embodiment.

[0042] Figure 3 FIG. 2 shows a system diagram of a low-energy multi-surface heating system 300 according to an embodiment.

[0043] Figure 4 FIG. 3 shows a flowchart of a method 400 for low-energy multi-surface heating according to an embodiment.

[0044] Figure 5 FIG. 4 is a block diagram of a controller 500 for multi-surface defogging and defrosting according to an embodiment. DETAILED DESCRIPTION

[0045] Various devices or processes will be described below to provide examples of each claimed embodiment. The embodiments described below do not limit any claimed embodiment, and any claimed embodiment may cover processes or devices different from those described below. A claimed embodiment is not limited to a device or process having all of the features of any one of the devices or processes described below, nor to the features common to multiple or all of the devices described below.

[0046] One or more of the systems described herein may be implemented in a computer program executable on a programmable computer, each programmable computer including at least one processor, a data storage system (including volatile and non-volatile memory and / or storage elements), at least one input device, and at least one output device. By way of example, and not limitation, the programmable computer may be a programmable logic unit, mainframe computer, server, and personal computer, cloud-based program or system, laptop computer, personal data assistant, cellular phone, smart phone, or tablet device.

[0047] Each program is preferably implemented in a high-level procedural or object-oriented programming and / or scripting language to communicate with the computer system. However, if desired, the program may be implemented in assembly or machine language. In any case, the language may be a compiled or interpreted language. Each such computer program is preferably stored on a storage medium or device readable by a general or special purpose programmable computer for configuring and operating the computer to perform the processes described herein when the storage medium or device is read by the computer.

[0048] The description of an embodiment with several components in communication with each other does not imply that all such components are required. Rather, various alternative components are described to illustrate the various possible embodiments of the present invention.

[0049] In addition, although process steps, method steps, algorithms, or the like may be described in sequence (in this disclosure and / or the claims), such processes, methods, and algorithms may be configured to work in an alternating sequence. In other words, any order or sequence of steps that may be described does not necessarily dictate a requirement to perform the steps in that order. The steps of the processes described herein may be executed in any feasible order. Additionally, some steps may be performed simultaneously.

[0050] When a single device or article is described herein, it will be readily apparent that more than one device / article (whether they cooperate or not) may be used in place of the single device / article. Similarly, where more than one device or article is described herein (whether they cooperate or not), it will be readily apparent that a single device / article may be used in place of the more than one device / article.

[0051] Although the apparatus and method have been described with reference to specific embodiments, it should be understood that these embodiments are merely illustrative of the principles and applications of the invention. Accordingly, it should be understood that numerous modifications may be made to the illustrative embodiments and other arrangements may be devised without departing from the spirit and scope of the invention as defined by the appended claims.

[0052] In this regard, the scope of the apparatus and process is not limited to the specific embodiments disclosed herein. Other variations, modifications, and alternatives are also within the scope of the apparatus and process. The appended claims are intended to cover these variations, modifications, and alternatives that fall within their true spirit and scope.

[0053] Furthermore, this disclosure is not limited to the methods, systems, apparatuses, and devices described, but includes their variations, modifications, and other uses that fall within the scope of the appended claims. The detailed description of the embodiments and the drawings are illustrative rather than restrictive.

[0054] For the present application, temperature control includes detection, defogging, and deicing. Deicing includes melting at least a portion of the ice accumulated on an exposed surface. Similarly, defogging or anti-fogging includes eliminating or preventing at least a portion of a fog or mist layer on a glass surface. The operations described for deicing or defogging include surface heating. The ablated or patterned surfaces described in this disclosure may be configured to provide surface heating or reduce heat loss through the glass. For the present application, detecting and removing frozen accumulations includes detecting or removing at least a portion of a fog or mist layer on a glass or other desired surface.

[0055] The following generally relates to systems, methods, and apparatuses for multi-surface deicing and defogging, and more particularly, to systems, methods, and apparatuses for providing low-energy defrosting and heating of multiple surfaces.

[0056] The electric windshield de-icing system operates based on the principle of resistive heating, where an electric current passes through a transparent electrically conductive coating in the windshield. The resistive heating is caused by the passage of the electric current, resulting in the melting of at least a portion of the ice accumulation on the outer surface of the windshield. The electric windshield defogging system operates based on a similar principle, where the transparent electrically conductive coating in the windshield is applied close to the glass layer exposed to the interior of the vehicle. The heat generated due to resistive heating at the interior glass layer controls the glass surface temperature near the dew point, thus defogging the surface.

[0057] When low-emissivity (Low-E) glass is incorporated into automotive windshields and windows, it confers a range of beneficial properties, such as enhanced thermal and energy protection, thus minimizing unwanted heat entry or exit within the vehicle. One of the distinguishing characteristics of Low-E glass is the deposition of a thin layer of metal or metal oxide, which acts as a reflective barrier against thermal radiation and blocks heat transfer, thus facilitating the control of heat flow into the vehicle interior. When exposed to solar radiation, the surface equipped with Low-E glass reflects the radiant heat, ensuring a moderate interior environment. Conversely, in colder climates, this glass minimizes heat outflow, thus keeping the interior warm. Additionally, Low-E glass plays a crucial role in blocking harmful ultraviolet (UV) radiation and infrared transmission while maintaining visible light transmission, thus ensuring protection for both the vehicle interior and its occupants from UV-induced damage. Overall, the incorporation of Low-E glass improves both thermal regulation and energy conservation, thus reducing the reliance on auxiliary heating or cooling within the vehicle. The additional features associated with UV and infrared reflection make Low-E glass useful in other applications, such as in the construction of buildings.

[0058] The low-emissivity coating of Low-E glass is applied using techniques such as pyrolysis or hard coating processes and magnetron sputtering vacuum deposition (MSVD). Common methods employed for the low-emissivity coating include pyrolytic layers, dual-silver MSVD, and triple-silver MSVD.

[0059] Systems and methods for de-icing windshields can utilize pulsed electrothermal de-icing (PETD). The PETD method can be applied to defrost heat exchangers in refrigeration systems or OHXs in EVs. Intelligent surface systems for detecting ice and providing rapid de-icing can be used on critical surfaces of aircraft, drones, buildings, wind turbines, and other surfaces requiring defrosting.

[0060] Systems and methods for de-icing a windshield using PETD provide a high heating power density (expressed in W / m^2), facilitating a fast and energy-efficient defrosting mechanism. A PETD-based de-icing system for a windshield utilizes resistive heating elements or conductive coatings embedded within or attached to the glass. When a pulsed current passes through these elements or coatings, heat is generated due to their inherent resistance. This heat warms the windshield, effectively melting and removing ice or frost that has formed on its surface.

[0061] To defrost a Low-E windshield or glass having a transparent conductive metal coating inside a glass laminate, a voltage is applied to the conductive layer. To minimize the heat used to remove frost, ice, and fog from the glass surface of a vehicle, a high power level of typically 4 kW or higher is applied to the metal layer. This is approximately the minimum power for complete defrosting and defogging of the windshield, without the need for supplementary air defrosting or defogging. For example, at -20 °C, a constant 48V system can use approximately 2 kW of power for defrosting.

[0062] Thus, current electric defrosting and defogging systems have a significant power consumption. In vehicles where energy conservation is important, such as electric vehicles, the large amount of power drawn from these systems can strain the main energy source, resulting in reduced performance or decreased driving range.

[0063] In addition, electric systems are inefficient at simultaneously providing defogging and defrosting for multiple surfaces. Challenges include efficiently distributing power between various surfaces and optimizing the electrical controller for multi-surface operation.

[0064] Figure 1 A block diagram illustrating a system 100 for controlling temperature including de-icing and defogging of an exposed surface is shown.

[0065] The system is configured to remove ice from a surface 110. The surface 110 can include a vehicle windshield, rear window, roof glass, aircraft windshield, and glass or similar materials used in buildings.

[0066] The system includes a current source 120. The current source 120 can be connected to a vehicle battery.

[0067] The current source 120 is further connected to a processing unit 130. The processing unit includes a processor 132 and a memory 134.

[0068] The surface 110 includes a transparent electro-conductive coating 142. Connectors 150 and 152 create a potential difference, resulting in as i xThe indicated current. The current source 120 can supply pulsed electrothermal de-icing (PETD) current to the connectors 150 and 152, causing current to flow and generating resistive heating of the surface 110 for de-icing. The current source includes direct current (DC). Other forms of current supplied by the current source include alternating current (AC), which is used to conveniently raise or lower voltage power. The current source includes multiple current types, with direct current (DC) being applied first. The preferred resistance characteristic of the heating track 140 is between 1 ohm and 100 ohms per square.

[0069] The system can include an impedance meter (not shown) that provides a capacitance level based on the phase difference between an AC excitation signal provided by an AC excitation source (not shown) and an induced current. The memory 134 can also store de-icing conditions based on the capacitance level or impedance level corresponding to the detected ice accumulation thickness. When the ice accumulation exceeds a threshold thickness, the de-icing condition can be satisfied, and the processor 132 can execute instructions to activate the current source 120 to supply current to the heating track 140 for de-icing. When the ice accumulation and thickness drop below the threshold thickness corresponding to the de-icing condition, the current source 120 can be deactivated.

[0070] Figure 2 A schematic diagram of an electronic device 200 according to an embodiment is shown. The electronic device 200 can perform any or all of the operations of the methods and features explicitly or implicitly described herein. For example, a computer equipped with network capabilities can be configured as the electronic device 200.

[0071] As shown in the figure, the device includes a processor 210 (such as a central processing unit (CPU) or a dedicated processor, such as a graphics processing unit (GPU) or other such processor unit), a memory 220, a non-transitory mass storage device 230, an I / O interface 240, a network interface 250, and a transceiver 260, all of which are communicatively coupled via a bidirectional bus 270.

[0072] According to certain embodiments, any or all of the depicted elements can be utilized, or just a subset of the elements. Additionally, the device 200 can include multiple instances of certain elements, such as multiple processors, memories, or transceivers. Further, the elements of the hardware device can be directly coupled to other elements without a bidirectional bus.

[0073] As an addition or alternative to the processor and memory, other electronic devices such as integrated circuits can be employed to perform the required logical operations.

[0074] The memory 220 may include any type of non-transitory memory, such as static random access memory (SRAM), dynamic random access memory (DRAM), synchronous DRAM (SDRAM), read-only memory (ROM), any combination thereof, or the like.

[0075] The mass storage element 230 may include any type of non-transitory storage device, such as a solid state drive, a hard disk drive, a disk drive, an optical disk drive, a USB drive, or any computer program product configured to store data and machine-executable program code. According to certain embodiments, statements and instructions executable by the processor 210 for performing any of the method operations described herein may be recorded on the memory 220 or the mass storage device 230.

[0076] Figure 3 A system diagram of a low-energy multi-surface heating system 300 according to an embodiment is shown.

[0077] The system 300 may be integrated to heat multiple surfaces in a passenger vehicle, a commercial truck, an aircraft, a ship, a train, or other vehicle. The system may also be integrated to heat multiple surfaces in a refrigeration device. Examples of surfaces that may be desired to be heated for defrosting and defogging include, but are not limited to, a windshield, glass, a roof glass, side windows, a rear window, a top window (sunroof or panoramic roof), an ADAS surface (camera or LiDAR), headlights, an external heat exchanger, brakes, an evaporator heat exchanger, etc.

[0078] Pulse high-power heating systems are efficient in keeping surfaces moisture-free, such as ice, frost, or fog condensation, while minimizing the energy consumption and time duration for operating these systems. Another advantage is that pulse high-power heating systems can provide a thermal barrier, which can significantly reduce the heating load inside the vehicle compartment. High power includes short bursts or pulses of energy, rather than continuous power. In certain embodiments, a continuous power source may be employed instead of pulsed power due to specific material characteristics or operating limitations.

[0079] The low-energy multi-surface heating system 300 provides pulsed power to multiple surfaces for resistive heating. During the pause between pulses at one surface, the system 300 directs a similar high power to another surface, thereby providing resistive heating to that another surface. In some embodiments, more than one surface may be activated simultaneously. Thus, the need for a surface to wait is removed.

[0080] System 300 includes a timing switch (not shown) in controller 304 that is programmed via an algorithm to govern the sequence and duration of pulsed power. When activated, the timing switch can direct a first power pulse to an initial surface. Once that pulse ends, the timing switch redirects subsequent pulses to a second surface based on a timing sequence. This sequence persists, where each surface receives its designated pulses, ensuring that each surface is fully addressed without any continuous electrical supply to any individual surface. This system, sequential approach ensures that each surface receives an optimal amount of heat for defrosting while maintaining energy efficiency and minimizing potential wear on any single surface.

[0081] In one embodiment, by using a timing switching component in an electric vehicle, pulsed power can be provided to the windshield as a first part of a sequence; thereafter, pulsed power can be provided to the front side windows as a second part of the sequence; thereafter, pulsed power can be provided to the rear seat side windows as a third part of the sequence; thereafter, pulsed power can be provided to the rear window as a fourth part of the sequence; thereafter, pulsed power can be provided to an ADAS surface (e.g., camera, LiDAR, etc.) as a fifth part of the sequence; thereafter, pulsed power can be provided to the headlight surface as a sixth part of the sequence; thereafter, pulsed power can be provided to the brakes as a seventh part of the sequence; thereafter, pulsed power can be provided to an external heat exchanger (heat pump system) as an eighth part of the sequence.

[0082] In one embodiment, when applied to a refrigeration system, the system provides high-power heating and defrosting to multiple heat exchangers by rotating power to each heat exchanger. Alternatively, each set of pulses can provide a complete defrosting / defogging process.

[0083] Since the low-energy multi-surface heating system 300 provides pulsed power to each surface that requires defrosting and defogging, the need for continuous power to any one surface is eliminated. In one embodiment, system 300 provides short-duration, high-power heating to create longer pauses between heating events.

[0084] Conversely, providing a longer duration and lower power is inefficient for defogging and defrosting because the low power may not be sufficient to achieve the desired heat, and a longer duration on one surface may not supply proper heating to other surfaces.

[0085] The low-energy multi-surface heating system includes a start switch 302. The start switch 302 operates as an activation point for the low-energy multi-surface heating system.

[0086] In various embodiments, the start switch can be implemented on a surface, while in other embodiments, the surface will automatically start based on ambient conditions such as temperature and / or humidity.

[0087] In an automobile, the activation switch 302 can include a manual or automatic switch (such as a dashboard button), or a touchscreen interface that allows the driver to click on a designated icon to activate the system, or a voice activation interface that utilizes voice recognition technology, or an automatic sensing device that automatically activates the system when a specific condition is detected (such as a certain drop in temperature, a certain change in relative humidity, or significant frosting). The automatic activation is based on detection conditions, such as the detection of ice, frost, or fog on a surface or a temperature threshold. The detection conditions or thresholds can be customized for each heating element.

[0088] The activation switch 102 is communicatively connected to the controller 104.

[0089] The system includes a controller 304. The controller 304 is configured to rotate the pulsed power supply to the heating elements 314, 316, 318, and 320, with at least one element connected to a target surface. The target surface can include the windshield, a handle, a rear window, etc. of a vehicle. In one embodiment, a single controller 304 manages and switches the power supply to multiple heating elements. Thus, by not providing a controller for each surface, an overall reduction in system components is achieved, thereby reducing the complexity and cost of a vehicle using such a system.

[0090] In various embodiments, the heating elements can include at least one of embedded wires, patterned conductive elements, or other conductive elements.

[0091] The controller 304 operates as the central processing unit of the low-energy multi-surface heating system 300.

[0092] The controller 304 continuously monitors the status of each target surface and the corresponding heating element using the sensor data 310 and the corresponding element information to determine the real-time demand for heating. The controller 304 is connected to each of the plurality of heating elements, and the plurality of heating elements are connected to the respective surfaces of the vehicle that require heating for defogging and defrosting.

[0093] The controller 304 is configured to adapt the power pulse frequency and duration depending on the sensed conditions to ensure optimal defrosting and defogging without wasting energy.

[0094] The controller 304 can provide energy management services. The controller 304 can adjust the energy distribution to ensure the most efficient use of the available power, thereby optimizing energy conservation.

[0095] The controller 304 prioritizes the direction of pulsed power to specific heating elements among the plurality of heating elements that use prioritized defrost or fog removal. For example, the user can prioritize removing frost from the windshield before removing frost from the rear window. The controller 304 can allow the user to manually set preferences, such as specific temperature thresholds for each surface.

[0096] The controller 304 provides error detection services. If a fault is detected in a surface heating element or any other component, the controller 304 can isolate that section, trigger an alarm, or switch to an alternative operating mode to prevent further complications or safety risks.

[0097] The controller 304 is configured to manage the power matrix 306 (a list of all elements) and determine which heating elements in the matrix need to be activated when it receives a start signal from the start switch 302. In one embodiment, the power matrix 306 includes a hierarchical arrangement or ordered list of all heating elements. The power matrix 306 includes a record of each heating element within the system, as well as their corresponding attributes. Attributes include, but are not limited to, maximum power per unit, peak power capacity, sensor-derived data, sensor readings, and specific energy requirements related to the defrosting and defogging functions. In one embodiment, when the controller 304 receives a start command via the start switch 302, it uses the matrix to determine and activate the appropriate heating elements based on the current operating needs.

[0098] The system includes a power queue 308 to effectively manage the power distribution between various surfaces. The identifiers of the heating elements that need to be activated are sent to the power queue 308. The controller 304 then activates the power converter 312 based on the power queue 308. The power converter 312 supplies power only to those heating elements identified in the power queue 308. In one embodiment, the power queue 308 is connected to the power matrix 306.

[0099] Based on the sensor data and the corresponding element information, the power queue 308 dynamically prioritizes which surface receives power first, thus ensuring that critical areas are processed immediately.

[0100] The power queue 308 schedules the power distribution to various surfaces, thus ensuring optimal power delivery at the appropriate time.

[0101] The power queue 308 provides feedback loop integration by operating with sensors and feedback loops. The power queue 308 can adjust the power distribution sequence based on current conditions, such as increased frost or reduced visibility or safety.

[0102] The power queue 308 manages the power distribution in sequence (one after another) or in parallel (multiple surfaces at a time) with various intensities.

[0103] The system includes a power converter 312. The power converter 312 is controlled by a controller 304. The power converter 312 receives power from a power source 322. The power converter 312 directs the power to the heating elements identified in the power queue 308 in a specific heating mode and for a specific power operation time.

[0104] In one embodiment, the determination of the specific heating mode and the corresponding operation time for each heating element is controlled by safety and two main categories of parameters. The first category includes the inherent characteristics of the element to be heated. The inherent characteristics include, but are not limited to, the size, shape, composition material, and curvature of the element. The second category includes the main operating conditions, such as the ambient temperature, the relative humidity in the surrounding environment, and the predetermined maximum temperature setting of the heating element. Under the direct control of the controller 304, the power converter 312 uses these parameters to determine and deliver the distribution and duration of power to the heating elements, as identified in the power queue 308, thus ensuring an optimized heating process suitable for the specific requirements of each individual element and environmental conditions.

[0105] The power converter 312 converts the power received from the power source 322 into a specific pulsed power voltage for the corresponding heating element.

[0106] The power converter 312 can convert the voltage level by raising or lowering the voltage level based on the needs of the target surface or the heating element. The power converter 312 can regulate and stabilize the current delivered to different surfaces, thus ensuring consistent and optimal heating.

[0107] Depending on the needs of the heating element, the power converter 312 converts the current type, thus converting AC (alternating current) to DC (direct current), or vice versa.

[0108] The power converter 312 changes the electrical frequency of the pulsed power.

[0109] The power converter 312 regulates the power delivery to ensure minimum energy waste, thus optimizing the energy efficiency of the system.

[0110] The power converter 312 provides pulsed electrothermal de-icing (PETD) current to the heating elements 314, 316, 318, and 320 to provide heat to a target surface (not shown) for defrosting and defogging.

[0111] The power converter 312 can be implemented in various forms to suit a specific application or vehicle. The implementations include a single AC power switch with direct conversion capabilities, a single DC power switch. In addition, more complex configurations can be implemented, such as any one or more of DC-DC, AC-DC, DC-AC, and AC-AC power converters. The implementations provide a range of conversion possibilities to adapt to the specific power requirements of vehicles, aircraft, or other appliances.

[0112] In addition, the power converter can be integrated into an existing system within a vehicle or appliance, thereby optimizing resource utilization. The integration can be achieved by completely repurposing or modifying an existing power converter within the vehicle or appliance, or by partially modifying them. In one embodiment, an on-board charger is modified to operate as the power converter of the present device and system. The existing power converter within the vehicle or appliance can be partially modified to include performing power factor correction to act as the power converter 312 of the present device and system.

[0113] The power source 322 supplies power to the low-energy multi-surface heating system. The power source 322 is a power storage component of the vehicle, such as a battery. The power source 322 includes a built-in energy storage mechanism, such as a battery or a capacitor. These storage units can be charged and discharged to provide power when needed. The power source 322 can deliver variable voltage and current outputs to adapt to the configuration of the power converter 312.

[0114] The power source 322 includes a plurality of output ports, each of which may deliver different voltages and power durations. The power converter 312 is connected to a plurality of power sources 322 having different voltage levels. Based on the component design, a plurality of power sources 322 are used for specific heating elements. The controller 304 is connected to a plurality of power converters 312, where each power converter is connected to a different power source 322.

[0115] The power converter 312 can be replaced by, or used in combination with, a DC switch and power for some or all of the heating elements. The DC switch and power can be used to provide or interrupt the path of DC voltage or current to the connected load or equivalent (such as another converter). The connected load includes the heating elements. The DC switch and power provide the ability to supply or block current and voltage in all directions. The aim is to provide high or low voltage interruption or supply for a bidirectional DC circuit to control the amount of power supplied to its connected load, thereby protecting it from surges or excessive incoming power. The time for such a switch to transition from a fully on state to a fully off state or vice versa is designed to meet the connected load and achieve its power protection / regulation goal. Additionally, such a DC switch can transition from a fully on state to a fully off state (or vice versa) in a rise or fall time that is significantly less than its conduction time. Alternatively, the DC switch can have a progressive linear or non-linear transition with a fixed or controllable slope. The DC switch can be implemented by means of a mechanically operated switch that is manually or automatically operated, by a control signal such as DC or AC or high or low voltage / current levels. The DC switch can also be implemented by means of a single electronic switch or a combination of electronic switches, such as back-to-back monolithic unidirectional power switches or monolithic bidirectional power switches. Similar functions can be achieved by controlling the output voltage / current or a multi-port DC-DC or AC-DC converter.

[0116] The system 300 includes a plurality of heating elements 313, 316, 318, and 320.

[0117] Each heating element is connected to a target surface (not shown) for providing a defogging and defrosting function by means of resistive heating. The target surface can include: a vehicle windshield, rear window, door handle, or other surface, where the vehicle includes cars, electric vehicles, trains, and marine vehicles; an aircraft windshield, wing, rotor; a building window; outdoor devices such as security cameras, lighting fixtures, electronic billboards, traffic signals; and evaporator coils in refrigeration and air conditioning systems.

[0118] The heating element includes an optically transparent electrically conductive coating (OTEC) material placed on the target surface (such as a windshield). However, depending on the specific nature and function of each heating element, not all elements within the system may be equipped with the OTEC material. The optically transparent electrically conductive coating (OTEC) material can be placed in an internal cross-sectional layer of the target surface. The optically transparent electrically conductive coating (OTEC) material includes a coating or film that, when applied to the target surface, allows electricity to pass through at least a portion of the coating on the target surface. When applied to the target surface, the coating allows visible light to pass completely through the target surface. When applied to the target surface, the coating allows light to pass through the target surface at least partially.

[0119] The heating elements 314, 316, 318, and 320 include electrical connectors (not shown) that are connected to the target surface and are used to apply current to the coating on the target surface. The connectors are connected to the target surface through corresponding bus bars (not shown).

[0120] Current is supplied to the electrically conductive coating of the heating element through the first bus bar. The first bus bar is electrically connected to the power converter 312. The first bus bar can be composed of a metal aluminum or copper strip or silver paste. The first bus bar receives current from the power converter 312 and distributes the current into the target surface through the coating of the heating element. When the power passes through the conductive material of the coating, heat is generated due to the resistivity of the electrically conductive coating, thereby causing de-icing of at least a portion of the ice or fog accumulated on the target surface. In one embodiment, applying heat similarly to other target surfaces causes defogging or defrosting of at least a portion of the fog collected on the other target surfaces. The current returns to the power converter 312 through the second bus bar connected to the second connector to complete the circuit.

[0121] In one embodiment, an alternative current receiving unit is used instead of the bus bar.

[0122] Each of the plurality of surfaces for heating is connected to at least one sensor for closed-loop feedback control for energy and time optimization. In one embodiment, a plurality of sensors are provided, which are configured to facilitate precise feedback control. The sensors include temperature sensors, including contact-based (such as thermocouples) and non-contact types (such as infrared sensors). In addition, the sensors include humidity sensors configured to monitor the ambient moisture level. In addition, the capabilities of the system are optimized by ultrasonic, piezoelectric, and capacitive sensors for detecting ice formation. In addition, the plurality of sensors include speed sensors for optimizing the performance of the system based on vehicle dynamics or other relevant speed-related parameters.

[0123] In one embodiment, the sensors are configured to provide collision detection and protection operations. The sensors can include piezoelectric sensors for pedestrian collision protection. The sensors can detect potential conflicts with pedestrians and activate preventive measures. The sensors can provide collision prevention by controlling critical systems such as ignition or anti-theft, thereby improving overall vehicle safety.

[0124] By providing heating control and regulation by means of closed-loop feedback control provided by sensors, the glass temperature can be maintained above the level of moisture accumulation, thereby enhancing the comfort inside the vehicle cabin. Moisture-free includes keeping the surface above 0 °C so that the surface is frost-free and at a controlled temperature near the dew point, thus protecting it from condensation and fogging. The system can also be configured to maintain a higher glass temperature to provide a thermal shield, thereby reducing heat loss through the window surface. In one embodiment, the higher temperature includes pulsating heat. This mode is quantitatively defined by a calculated ratio based on the relationship between the average temperature and the peak-to-peak temperature change. Thus, an accurate understanding and control of the heat output are provided, ensuring that the system maintains an optimized temperature distribution, which is particularly beneficial for applications that require enhanced heat retention or shielding properties. In one embodiment, the defrost temperature is higher than the defog temperature. Preferably, the temperature is set to maximize passenger comfort while minimizing the heat in the vehicle cabin from the HVAC. This can enhance the comfort of the passengers, especially when the head, neck, or shoulders of the passengers are close to the window surface. Although generating a thermal shield via a heated window around the passengers will increase the comfort of the passengers, it may also reduce the heating load on the HVAC heating system, thereby saving energy, especially at cold temperatures when the power consumption for heating purposes is higher than normal. Overall, this may increase the driving range of an electric vehicle.

[0125] The type of thermal shield can be generated using various window combinations depending on the external temperature and the number of passengers. The thermal shield can be generated by heating only a single window surface or any combination of window surfaces to reduce the heat loss from the (one or more) passengers closest to the vehicle at that time.

[0126] Multiple sensors (not shown) are connected to each heating element or the corresponding surface.

[0127] The multiple sensors include temperature sensors that are used to measure the exact temperature of the surface to determine whether it is below the freezing point.

[0128] The multiple sensors include humidity sensors that are used to detect the moisture level, which can indicate the formation or likelihood of fog or frost.

[0129] The multiple sensors include impedance sensors that are used to measure the electrical impedance of the surface, which can vary based on the presence of moisture or frost.

[0130] The multiple sensors include optical sensors that are used to detect visible obstructions on the surface, such as frost, fog, or ice.

[0131] The multiple heating surfaces connected to the system can use various types of conductive materials. The conductive materials on different heating surfaces can include different levels of sheet resistance, measured in ohms per square. Since each heating surface will have a different surface area, the heating intensity can be optimized by selecting a suitable conductive material for coating, selecting the surface area for coating, selecting the bus bar position, and adjusting the resistance level to achieve a target resistance level. In one embodiment, the resistance across various heating surfaces within the system is established to obtain a predefined power output, ranging from a minimum of 4 kilowatts per square meter to a maximum that can reach up to 15 kilowatts per square meter. This resistance level depends on the available voltage level within the vehicle, which mainly includes a high-voltage system but may also include a low-voltage configuration. Ohm's law, expressed as V = I * R, is referenced during this process to ensure that the current (I) and resistance (R) are appropriately adjusted to align with the voltage (V) parameters of the vehicle's electrical system. In one embodiment, the determination of the resistance within the heating surfaces of the system is based on achieving a specific power per unit area target. This target is defined by the desired heat output relative to the surface area of each individual heating element, thus ensuring optimal energy distribution according to the design parameters of the system.

[0132] Overall, the heating intensity should be optimized such that a similar power level is delivered to each surface with a minimum amount of energy, thereby keeping each surface free of frost and fog. A wider range of resistance (R) allows for the application of a wider range of voltage (V), which can be used to achieve optimal power acquisition, thus improving the thermal efficiency of the system.

[0133] The low-energy multi-surface heating system provides heating to at least one of the multiple heating elements connected to the respective surfaces. The heating elements can have different sizes, materials, and conductive coatings and possess different physical, mechanical, or electrical properties. One embodiment includes a windshield that consists of glass incorporating an optically transparent electro-conductive (OTEC) layer, which is typically silver-based and covers the entire size of the windshield. For a passenger vehicle, the windshield size is approximately 0.7 meters by 1.4 meters. Another example includes an ADAS surface, which may be prepared from polycarbonate and employs an alternative coating, such as carbon nanotubes (CNT), over a significantly smaller area, with each dimension spanning only a few centimeters.

[0134] The controller 304 calculates the corresponding parameters for each element based on the corresponding element information. The corresponding element information includes the element size, element material, and the physical, mechanical, or electrical properties of the element. The corresponding element information includes sensor data 310. The sensor data 310 includes impedance measurements and temperature measurements. By dynamically selecting the power level and duration based on the corresponding element information, the controller reduces energy consumption by activating the heating elements in the power queue 308 and providing a specific heating pattern and runtime.

[0135] The controller 304 is configured to execute a predetermined heating mode including time and voltage for implementing a heating mode. Additionally, the controller 304 may be configured to collect capacitance values of a target surface from the sensors and sensor data 310 to determine the volume of ice accumulated on these portions.

[0136] The heating mode and the operating time are customized for each heating element based on the corresponding component information.

[0137] Some heating elements may require a single thermal pulse or multiple thermal pulses with a specific fixed or variable frequency and amplitude to remove accumulated frost or fog.

[0138] Some heating elements may have a ramp-up at the start of power application to avoid any thermal shock to the element, which may generate thermal stress and reduce long-term durability.

[0139] Figure 4 A flowchart of a method 400 for low-energy multi-surface heating according to an embodiment is shown.

[0140] The method 400 can be integrated to heat multiple surfaces in a passenger vehicle, a commercial truck, an aircraft, a ship, a train, or other vehicles. The system can also be integrated to heat multiple surfaces in a refrigeration device. Examples of surfaces that may be heated for defrosting and defogging include but are not limited to windshields, glass, side windows, rear windows, roof windows (sunroofs or panoramic roofs), ADAS surfaces (cameras or LiDARs), headlights, external heat exchangers, brakes, evaporator heat exchangers, etc.

[0141] The pulsed high-power heating system is efficient in keeping the surface free of moisture such as ice, frost, or fog condensation, while minimizing the energy consumption and time duration for operating these systems. High power includes short bursts or pulses of energy rather than continuous power.

[0142] The low-energy multi-surface heating method 400 includes providing pulsed power to multiple surfaces for resistive heating. During the pause between pulses at one surface, the method 400 provides directing similar high power to another surface, thereby providing resistive heating to the other surface.

[0143] When applied to a refrigeration system, the system provides high-power heating and defrosting for multiple heat exchangers by rotating the power to each heat exchanger.

[0144] At 402, a start signal is sent to the controller to activate the low-energy multi-surface heating system.

[0145] In an automobile, the activation signal can be initiated by an activation switch. The activation switch 302 can include a manual or automatic switch (such as a dashboard button), or a touchscreen interface that allows the driver to click on a designated icon to activate the system, a voice activation interface using voice recognition technology, or an automatic sensing device that automatically activates the system when a specific condition is detected (such as a certain drop in temperature or significant frosting). The automatic activation is based on detection conditions, such as the detection of ice, frost, or fog on the surface or a temperature threshold. The detection conditions or thresholds can be customized for each heating element.

[0146] At 404, upon receiving the activation signal, the controller manages the power matrix (a list of all elements) and determines which heating elements in the matrix need to be activated.

[0147] In various embodiments, the heating elements can include at least one of embedded wires, patterned conductive elements, or other conductive elements.

[0148] 404 includes controlling the sequence and duration of pulsed power by means of a timing switch programmed with an algorithm. Upon activation, the timing switch can direct the first power pulse to the initial surface. Once that pulse ends, the timing switch redirects subsequent pulses to the second surface based on the timing sequence. This sequence persists, where each surface receives its designated pulse, thus ensuring that each surface is fully addressed without any continuous electrical supply to any individual surface. This systematic, sequential approach ensures that each surface receives the optimal amount of heat for defrosting while maintaining energy efficiency and minimizing potential wear on any single surface.

[0149] By using a timing switching component in an electric vehicle, pulsed power can be provided to the windshield as the first part of the sequence; thereafter, pulsed power can be provided to the front side windows as the second part of the sequence; thereafter, pulsed power can be provided to the rear seat side windows as the third part of the sequence; thereafter, pulsed power can be provided to the rear window as the fourth part of the sequence; thereafter, pulsed power can be provided to the ADAS surface (e.g., cameras, LiDAR, etc.) as the fifth part of the sequence; thereafter, pulsed power can be provided to the headlight surface as the sixth part of the sequence; thereafter, pulsed power can be provided to the brakes as the seventh part of the sequence; thereafter, pulsed power can be provided to the external heat exchanger (heat pump system) as the eighth part of the sequence.

[0150] 404 includes rotating the pulsed power supply to the heating elements, where at least one element is connected to the target surface. The target surface can include the windshield, handles, rear window, etc. of the vehicle.

[0151] At 406, sensor data from the plurality of heating elements is sent to the controller.

[0152] 406 includes continuously monitoring the status of each target surface and corresponding heating element using sensor data and corresponding component information to determine real-time heating targets.

[0153] 406 includes adapting the power pulse frequency and duration depending on the sensed conditions to ensure optimal defrosting and defogging without wasting energy.

[0154] 406 includes adjusting the energy distribution to ensure the most efficient use of the available power and thus optimize energy savings.

[0155] 406 includes prioritizing the direction of pulsed power to specific heating elements among the plurality of heating elements for prioritized frost or fog removal. For example, the user can prioritize removing frost from the windshield before removing frost from the rear window. The controller can allow the user to manually set preferences such as specific temperature thresholds for each surface.

[0156] At 408, a power queue is determined to manage the power distribution between various surfaces.

[0157] Identifiers of heating elements to be activated are sent to the power queue.

[0158] 408 includes dynamically prioritizing which surface receives power first based on sensor data and corresponding component information, thus ensuring that critical areas are processed immediately.

[0159] 408 includes calculating corresponding parameters for each element based on the corresponding component information. The corresponding component information includes element size, element material, and physical, mechanical, or electrical properties of the element. The corresponding component information includes sensor data. The sensor data includes impedance measurements and temperature measurements. By dynamically selecting the power level and duration based on the corresponding component information, the controller reduces energy consumption by activating the heating elements in the power queue and providing specific heating patterns and run times.

[0160] The plurality of heated surfaces connected to the system can use various types of conductive materials. The conductive materials on different heated surfaces can include different levels of sheet resistance, measured in ohms per square. Since each heated surface will have a different surface area, the heating intensity can be optimized by selecting a suitable conductive material for coating, selecting the surface area for coating, selecting the busbar position, and adjusting the resistance level to achieve a target resistance level. Overall, the heating intensity can be optimized such that a similar power level is delivered to each surface with a minimum amount of energy, thus keeping each surface free of frost and fog.

[0161] A low-energy multi-surface heating system provides heating to at least one of the plurality of heating elements connected to respective surfaces. The heating elements can have different sizes, materials, and conductive coatings, and have different physical, mechanical, or electrical properties.

[0162] At 410, the controller activates the power converter based on the power queue.

[0163] 410 includes scheduling power distribution to various surfaces based on the power queue to ensure optimal power delivery at the appropriate time.

[0164] 410 includes operating with sensors and feedback loops through the power queue to provide feedback loop integration. The power queue can adjust the power distribution sequence based on current conditions such as increased frost or reduced visibility or security.

[0165] 410 includes managing power distribution in sequence (one after another) or in parallel (multiple surfaces at a time) with various intensities by means of the power queue.

[0166] At 412, the power converter supplies power to the heating elements identified in the power queue.

[0167] 412 includes directing power to the heating elements identified in the power queue 308 in a specific heating mode and power operation time.

[0168] 412 includes converting the power received from the power source into a specific pulsed power voltage for the respective heating elements.

[0169] In some embodiments, 412 may include converting the voltage level by raising or lowering the voltage level based on the target surface or heating element. The power converter can regulate and stabilize the current delivered to different surfaces to ensure consistent and optimal heating.

[0170] 412 includes converting the current type depending on the configuration of the heating element, including converting AC (alternating current) to DC (direct current), or vice versa.

[0171] 412 includes changing the electrical frequency of the pulsed power.

[0172] 412 includes regulating power delivery to ensure minimum energy waste and optimize the energy efficiency of the system.

[0173] 412 includes providing pulsed electrothermal de-icing (PETD) current to the heating elements to provide heat to the target surface for defrosting and defogging.

[0174] The method is applied to a plurality of heating elements.

[0175] Each heating element is connected to a target surface for providing a defogging and defrosting function by means of resistive heating. The target surface can include: a vehicle windshield, a rear window, a door handle, or other surfaces, and the vehicle includes an automobile, an electric vehicle, a train, and a marine vehicle; an aircraft windshield, a wing, a rotor; a building window; outdoor devices such as a security camera, a lighting device, an electronic billboard, a traffic signal; and an evaporator coil in a refrigeration and air conditioning system.

[0176] The heating element includes an optically transparent conductive coating (OTEC) material placed on a target surface (such as a windshield). The optically transparent conductive coating (OTEC) material can be placed in an internal cross-sectional layer of the target surface. The optically transparent conductive coating (OTEC) material includes a coating or a film that, when applied to the target surface, allows electricity to pass through at least a portion of the coating on the target surface. When applied to the target surface, the coating allows visible light to pass through the target surface. When applied to the target surface, the coating allows light to pass through the target surface at least partially.

[0177] By providing heating control and regulation by means of closed-loop feedback control provided by a sensor, the glass temperature can be maintained above the level of moisture accumulation, thereby improving the comfort inside the vehicle compartment. The absence of moisture includes keeping the surface above 0 °C so that the surface is frost-free and at a controlled temperature near the dew point, thus protecting it from condensation and fogging. The system can also be configured to maintain a higher glass temperature to provide a thermal shield, thereby reducing heat loss through the window surface. This can improve the comfort of passengers, especially when the head, neck, or shoulders of a passenger are close to the window surface. Although generating a thermal shield via a heated window around a passenger will increase the comfort of the passenger, it may also reduce the heating load on the HVAC heating system, thereby saving energy, especially at cold temperatures when the power consumption for heating purposes is higher than normal. Overall, this may increase the driving range of an electric vehicle.

[0178] The type of thermal shield can be generated using multiple window combinations depending on the external temperature and the number of passengers. The thermal shield can be generated by heating only a single window surface or any combination of window surfaces to reduce the heat loss of the (one or more) passengers closest to the vehicle at that time. Advantageously, a single system connected to multiple heating elements and surfaces improves thermal efficiency while reducing energy use. As a result, the number of components required to power multiple surfaces is reduced, thereby improving the overall system efficiency.

[0179] Figure 5 is a block diagram of a controller 500 for multi-surface defogging and defrosting according to an embodiment. The controller 500 can be Figure 3 the controller 304 shown in

[0180] The controller 500 includes a memory 510, a processor 520, and a database 532. According to other embodiments, the database 532 may be hosted by a separate server connected to the controller 500.

[0181] The controller 500 may be integrated to heat multiple surfaces in a passenger vehicle, commercial truck, airplane, ship, train, or other vehicle. The system may also be integrated to heat multiple surfaces in a refrigeration device. Examples of surfaces that may be heated for defrosting and defogging include, but are not limited to, windshields, glass, side windows, rear windows, roof windows (sunroofs or panoramic roofs), ADAS surfaces (cameras or LiDAR), headlights, external heat exchangers, brakes, evaporator heat exchangers, etc.

[0182] The pulsed high-power heating system is efficient in keeping surfaces free of moisture, such as ice, frost, or fog condensation, while minimizing the energy consumption and time duration for operating these systems. High power includes short bursts or pulses of energy, rather than continuous power.

[0183] The low-energy multi-surface heating controller 500 is configured to provide pulsed power to multiple surfaces for resistive heating. During the pause between pulses at one surface, the controller 500 provides similar high power directed to another surface, thereby providing resistive heating to that other surface.

[0184] When applied to a refrigeration system, the controller 500 provides high-power heating and defrosting to multiple heat exchangers by rotating the power to each heat exchanger.

[0185] The controller 500 includes a processing module 522. The processing module 522 is configured to activate the low-energy multi-surface heating function upon receipt of a start signal.

[0186] The controller 500 includes a power matrix module 524. The power matrix module 524 is configured to manage the power matrix (a list of all elements) upon receipt of a start signal and determine which heating elements in the matrix need to be activated.

[0187] The power matrix module 524 is configured to control the sequence and duration of pulsed power by means of a timing switch programmed with an algorithm. Upon activation, the timing switch may direct a first power pulse to an initial surface. Once that pulse ends, the timing switch redirects subsequent pulses to a second surface based on a timing sequence. This sequence persists, where each surface receives its designated pulse, thereby ensuring that each surface is adequately addressed without any continuous electrical supply to any individual surface. This systematic, sequential approach ensures that each surface receives the optimal amount of heat for defrosting while maintaining energy efficiency and minimizing potential wear on any single surface.

[0188] By using a timed switching component in an electric vehicle, pulsed power is provided to the windshield as the first part of a sequence; thereafter, pulsed power can be provided to the front side windows as the second part of the sequence; thereafter, pulsed power can be provided to the rear seat side windows as the third part of the sequence; thereafter, pulsed power can be provided to the rear window as the fourth part of the sequence; thereafter, pulsed power can be provided to the ADAS surfaces (e.g., cameras, LiDAR, etc.) as the fifth part of the sequence; thereafter, pulsed power can be provided to the headlight surfaces as the sixth part of the sequence; thereafter, pulsed power can be provided to the brakes as the seventh part of the sequence; thereafter, pulsed power can be provided to the external heat exchanger (heat pump system) as the eighth part of the sequence.

[0189] The power matrix module 524 is configured to rotate the pulsed power supply to the heating elements, where at least one element is connected to the target surface. The target surface can include the vehicle's windshield, handle, rear window, etc.

[0190] The controller 500 includes a sensor data collection module 522. The sensor data collection module 522 is configured to receive sensor data from the plurality of heating elements.

[0191] The sensor data collection module 522 is configured to continuously monitor the state of each target surface and the corresponding heating element using the sensor data and the corresponding element information to determine the real-time usage of heating.

[0192] The sensor data collection module 522 is configured to adapt the power pulse frequency and duration depending on the sensed conditions to ensure optimal defrosting and defogging without wasting energy.

[0193] The sensor data collection module 522 is configured to adjust the energy distribution to ensure the most efficient use of the available power, thereby optimizing energy conservation.

[0194] The sensor data collection module 522 is configured to prioritize the direction of the pulsed power to specific heating elements among the plurality of heating elements for prioritized frost or fog removal. For example, the user can prioritize removing frost from the windshield before removing frost from the rear window. The controller can allow the user to manually set preferences, such as specific temperature thresholds for each surface.

[0195] The controller 500 includes a power queue module 528. The power queue module 528 is configured to determine a power queue to manage the power distribution between the individual surfaces.

[0196] The identifier of the heating element to be activated is sent to the power queue.

[0197] The power queue module 528 is configured to dynamically prioritize which surface receives power first based on sensor data and corresponding component information, thus ensuring that critical areas are processed immediately.

[0198] The power queue module 528 is configured to calculate corresponding parameters for each component based on the corresponding component information. The corresponding component information includes component size, component material, and physical, mechanical, or electrical properties of the component. The corresponding component information includes sensor data. The sensor data includes impedance measurements and temperature measurements. By dynamically selecting the power level and duration based on the corresponding component information, the controller reduces energy consumption by activating heating elements in the power queue and providing specific heating patterns and run times.

[0199] The multiple heating surfaces connected to the system can use various types of conductive materials. The conductive materials on different heating surfaces can include different levels of sheet resistance, measured in ohms per square. Since each heating surface will have a different surface area, the heating intensity can be optimized by selecting a suitable conductive material for coating, selecting the surface area for coating, selecting the busbar position, and adjusting the resistance level to achieve a target resistance level. Overall, the heating intensity should be optimized such that a similar power level is delivered to each surface with a minimum amount of energy, thus keeping each surface free of frost and fog.

[0200] The low - energy multi - surface heating system provides heating to at least one of the multiple heating elements connected to the corresponding surfaces. The heating elements can have different sizes, materials, and conductive coatings and possess different physical, mechanical, or electrical properties.

[0201] The controller 500 includes a power converter module 530. The power converter module 530 is configured to activate the power converter based on the power queue.

[0202] The power converter module 530 is configured to schedule power distribution to various surfaces based on the power queue, thus ensuring optimal power delivery at the appropriate time.

[0203] The power converter module 530 is configured to operate with sensors and feedback loops through the power queue to provide feedback loop integration. The power queue can adjust the power distribution sequence based on current conditions such as increased frost or reduced visibility.

[0204] The power converter module 530 is configured to manage power distribution in sequence (one after another) or in parallel (multiple surfaces at a time) with various intensities by means of the power queue.

[0205] The power converter module 530 is configured to supply power to the heating elements identified in the power queue.

[0206] The power converter module 530 is configured to direct power to the heating elements identified in the power queue 308 in a specific heating mode and power operation time.

[0207] The power converter module 530 is configured to convert the power received from the power source into a specific pulsed power voltage for the respective heating elements.

[0208] In some embodiments, the power converter module 530 is configured to convert the voltage level by raising or lowering the voltage level based on the target surface or heating element. The power converter can regulate and stabilize the current delivered to different surfaces, thus ensuring consistent and optimal heating.

[0209] The power converter module 530 is configured to convert the current type depending on the configuration of the heating element, including converting AC (alternating current) to DC (direct current), or vice versa.

[0210] The power converter module 530 is configured to change the electrical frequency of the pulsed power.

[0211] The power converter module 530 is configured to regulate power delivery to ensure minimum energy waste and optimize the energy efficiency of the system.

[0212] The power converter module 530 is configured to supply pulsed electrothermal de-icing (PETD) current to the heating elements to provide heat to the target surface for defrosting and defogging.

[0213] The method is applied to multiple heating elements.

[0214] Each heating element is connected to the target surface to provide defogging and defrosting functions by means of resistive heating. The target surface can include: vehicle windshields, rear windows, door handles or other surfaces, vehicles including cars, electric vehicles, trains and marine vehicles; aircraft windshields, wings, rotors; building windows; outdoor devices such as security cameras, lighting devices, electronic billboards, traffic signals; and evaporator coils in refrigeration and air conditioning systems.

[0215] The heating element includes an optically transparent conductive coating (OTEC) material placed on the target surface (such as a windshield). The optically transparent conductive coating (OTEC) material can be placed in the internal cross-sectional layer of the target surface. The optically transparent conductive coating (OTEC) material includes a coating or film that allows electricity to pass through at least a portion of the coating on the target surface when applied to the target surface. When applied to the target surface, the coating allows visible light to pass through the target surface. When applied to the target surface, the coating allows light to pass through the target surface at least partially.

[0216] By providing heating control and regulation by means of closed-loop feedback control provided by sensors, the glass temperature can be maintained above the level of moisture accumulation, thereby improving the comfort inside the vehicle compartment. Moisture-free includes keeping the surface above 0°C so that the surface is frost-free and at a controlled temperature near the dew point, thus protecting it from condensation and fogging. The system can also be configured to maintain a higher glass temperature to provide a thermal shield, thereby reducing heat loss through the window surface. This can improve the comfort of passengers, especially when the head, neck, or shoulders of the passengers are close to the window surface. Although generating a thermal shield via a heated window around the passengers will increase the comfort of the passengers, it may also reduce the heating load on the HVAC heating system, thereby saving energy, especially at cold temperatures when the power consumption for heating purposes is higher than normal. Overall, this may increase the driving range of the electric vehicle.

[0217] The type of thermal shield can be generated using multiple window combinations depending on the external temperature and the number of passengers. The thermal shield can be generated by heating only a single window surface or any combination of window surfaces to reduce the heat loss of the (one or more) passengers closest to the vehicle at that time.

[0218] The database 532 includes heating element information 534. The corresponding element information includes the element size, element material, and the physical, mechanical, or electrical properties of the element. The corresponding element information includes sensor data. The sensor data includes impedance measurements and temperature measurements. By dynamically selecting the power level and duration based on the corresponding element information, the controller reduces energy consumption by activating the heating elements in the power queue 308 and providing a specific heating mode and runtime.

[0219] The database 532 includes a defrost threshold 536. The defrost threshold 536 includes a predefined temperature or condition at which the device activates its defrost mechanism. The threshold is determined based on the temperature or moisture level at which frost or ice begins to form or affects visibility or functionality. For example, the threshold can be set slightly above 0°C (the freezing point of water) to ensure that the surface remains free of frost or ice. In addition to temperature, humidity levels can also be considered because even at temperatures slightly above freezing, higher humidity can cause condensation and frosting. The defrost threshold can be used to ensure the efficient operation of the system, activate only when necessary to save energy, and ensure the safety and comfort of the vehicle occupants or the efficiency of the equipment.

[0220] The database 532 includes a defogging threshold 538. The defogging threshold 536 includes predetermined conditions that are primarily related to humidity and temperature, under which the defogging system triggers its defogging mechanism. This threshold is typically determined by identifying the conditions under which moisture begins to condense on a surface, leading to fogging. For example, when the relative humidity inside a vehicle or device reaches a certain percentage and the temperature is within a specific range, the threshold can be set to activate defogging measures. Fogging typically occurs when warm, moist air comes into contact with a cooler surface, causing condensation. By setting an appropriate defogging threshold, the system can proactively address visibility or functionality issues before they become problematic, thus ensuring optimal safety, comfort, and efficiency without unnecessary energy consumption.

[0221] While the foregoing description provides examples of one or more devices, methods, or systems, it will be appreciated that, as interpreted by those skilled in the art, other devices, methods, or systems may also fall within the scope of the claims.

Claims

1. A system for temperature control on multiple surfaces, the system comprising: a plurality of conductive elements coupled to the plurality of surfaces; a power supply unit conductively connected to each of the plurality of conductive elements, the power supply unit being configured to heat each of the plurality of conductive elements; as well as a controller unit connected to the power supply unit, the controller unit being configured to activate the power supply unit for selectively heating each of the plurality of conducting elements, Therein, multiple conducting elements are controlled by a single controller unit for low energy defrosting and demisting.

2. The system of claim 1, wherein: The plurality of conductive elements include a plurality of material properties including size, constituent material, electrical conductivity, electrical resistance, thermal coefficient, and structural dimensions.

3. The system of claim 2, wherein: The controller unit is automatically activated based on detection of an environmental condition on the each of the plurality of conductive elements, wherein the environmental condition comprises at least one of: ice, frost, fog, moisture, relative humidity, and a temperature threshold.

4. The system of claim 3, wherein: The system also includes a power queuing unit configured to identify the selective heating of each of the plurality of conductive elements based on the plurality of material properties and the environmental condition of each of the plurality of conductive elements.

5. The system of claim 4, wherein: The plurality of conductive elements are connected to a plurality of corresponding sensors to detect an environmental condition of the each conductive element of the plurality of conductive elements.

6. The system of claim 5, wherein: The controller unit is connected to a sensor unit, wherein the sensor unit is configured to collect detected environmental conditions from the plurality of corresponding sensors.

7. The system of claim 1, wherein: The power supply unit includes a plurality of power sources corresponding to the each of the plurality of conductive elements.

8. A method for detecting and removing frozen accumulations from a plurality of surfaces, the method comprising: sending sensor data from the plurality of conducting elements to a power supply unit; determining, from a power matrix, heating elements in the power matrix that are required to be activated and determining the amount of energy required by the heating elements, wherein the heating elements are connected to corresponding conductive elements designated for heating; receiving, by the controller, a start signal to activate the low energy multi-surface heating system, wherein the plurality of conductive elements are connected to the plurality of surfaces, and the power supply unit is conductively connected to each of the plurality of conductive elements; determining, by the power queue, power management and distribution among the plurality of conducting elements designated for heating and a sequence of supplying power to the heating elements for achieving optimal time utilization and rapid de-icing and defrosting; and A power converter is activated based on the power queue, wherein the power queue is configured to activate power delivery to the conductive element designated for heating.

9. The method of claim 8, wherein: The plurality of conductive elements include a plurality of material properties for adjusting resistance according to the surface, the plurality of material properties including size, constituent material, conductivity, resistance, thermal coefficient, and structural dimensions.

10. The method of claim 9, wherein: The power supply unit is automatically activated based on detection of an environmental condition on each of the plurality of conductive elements, wherein the environmental condition comprises at least one of: ice, frost, fog, moisture, relative humidity, and a temperature threshold.

11. The method of claim 10, wherein: The method further includes identifying the selective heating of each of the plurality of conductive elements based on the plurality of material properties and the environmental condition of each of the plurality of conductive elements.

12. The method of claim 11, wherein: The plurality of conductive elements are connected to a plurality of corresponding sensors to detect an environmental condition of the each conductive element of the plurality of conductive elements.

13. The method of claim 12, wherein: The power supply unit is connected to a sensor unit, wherein the sensor unit is configured to collect detected environmental conditions from the plurality of corresponding sensors.

14. The method of claim 8, wherein: The power supply unit includes a plurality of power sources corresponding to the each of the plurality of conductive elements.

15. An apparatus for detecting and removing frozen accumulations from a plurality of surfaces, the apparatus comprising: a processing module configured to activate the low energy multi-surface heating function upon receiving the activation signal, wherein a plurality of conductive elements are connected to the plurality of surfaces and a power supply unit is conductively connected to each conductive element of the plurality of conductive elements; a power matrix module configured to manage a power matrix and determine which heating elements in the matrix need to be activated, wherein the power matrix includes conductive elements designated for heating; a sensor data collection module configured to receive sensor data transmitted from the plurality of conductive elements to the power supply unit; a power queue module configured to determine a power queue to manage power distribution among the conductive elements designated for heating; and A power converter module is configured to activate a power converter based on the power queue, wherein the power queue is configured to activate power delivery to the conductive element designated for heating.

16. The device of claim 15, wherein: The plurality of conductive elements include a plurality of material properties including size, constituent material, electrical conductivity, electrical resistance, thermal coefficient, and structural dimensions.

17. The device of claim 16, wherein: The device is automatically activated based on detecting an environmental condition on each of the plurality of conductive elements, wherein the environmental condition comprises at least one of: ice, frost, fog, moisture, relative humidity, and a temperature threshold.

18. The device of claim 17, wherein: The plurality of conductive elements are connected to a plurality of corresponding sensors to detect an environmental condition of the each conductive element of the plurality of conductive elements.

19. The device of claim 18, wherein: The sensor data collection module is connected to a sensor unit, wherein the sensor unit is configured to collect detected environmental conditions from the plurality of corresponding sensors.

20. The device of claim 19, wherein: The power converter module is connected to a plurality of power sources corresponding to the each of the plurality of conduction elements, and wherein the power converter comprises a modified power converter of a target vehicle or appliance.

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