Innovative Technology Achieves Quick Frost Removal for Car Windows in One Minute Using 48V Power Supply Network

The traditional method for defrosting car windows involves channeling the excess heat generated by an internal combustion engine (ICE) to the windshield. However, this method is inefficient and leads to uneven heat distribution on the glass surface. As electric vehicles become more prevalent, the cabin climate systems powered by batteries have adopted this defrosting technique. Yet, due to the quieter and more sealed nature of electric vehicle cabins, the issue of fogging on windows has become more pronounced. This necessitates a rethinking of defrosting solutions to prevent rapid ice formation on windshields during winter, which can severely obstruct visibility while driving.

Moreover, with the shift towards electrification in vehicles, the “free” residual heat generated by traditional internal combustion engines will no longer be available. Electric vehicles must draw energy from their main battery for defrosting, consuming valuable electrical energy that could otherwise drive the vehicle. To address the defrosting challenge, Betterfrost Technology has developed an innovative solution that employs proprietary algorithms and a high-density power conversion module to deliver pulse power, claiming to defrost car windows in just 60 seconds while consuming only one-twentieth of the energy used by existing HVAC defrost systems.

Founded in 2015 by the Ice, Climate and Environment (ICE) Lab at Dartmouth College, Betterfrost Technology’s innovative defrosting solution does not require complete melting of the ice layer on the windshield. Instead, it weakens the adhesion between the ice and the glass surface. This is achieved by sending short and controllable pulse power to the glass surface, creating a thin quasi-liquid layer beneath the ice, allowing it to detach from the windshield without the need for heating the entire surface.

Many windshields and sunroofs are coated with low-emissivity (low-E) conductive layers made from materials like silver or indium tin oxide, which serve as electrical pathways for Betterfrost’s proprietary power control algorithm. Compared to traditional HVAC systems that take about 25 minutes to defrost, this algorithm claims to remove ice from the windshield in just one minute while consuming approximately 95% less energy than internal combustion vehicles.

This technology ensures uniform heat distribution across the glass surface, minimizing stress that could lead to glass breakage. In environments as cold as -20°C, it can also reduce the cabin heating demand by 27%, directly extending the electric vehicle’s range. Additionally, it eliminates the need for noisy blower motors and bulky ductwork, enhancing passenger comfort and saving valuable space for vehicle engineers to utilize for other purposes.

Betterfrost’s technology could also replace the costly glycol sprays used for de-icing aircraft wings, eliminate dangerous ice build-up on wind turbine blades, and lower refrigeration costs in cold storage facilities through more efficient defrosting.

A key component of the Betterfrost solution is its 48V power network. To achieve this, they employ a high-power density automotive-grade 800V/400V to 48V fixed ratio Vicor BCM bus converter, which provides safe and efficient high-speed pulses to the glass surface.

The Vicor BCM6135 has a power density of 3.4 kW/in³ and functions like a DC-DC transformer, where the voltage applied at the high voltage input is converted to the low voltage side according to the module’s conversion ratio (K factor). For instance, with a K of 1/16 and an input voltage of 800V, the output voltage would be 50V. This module meets strict creepage and clearance standards in a compact form factor, being 90% smaller than traditional DC-DC converters.

Betterfrost is currently in discussions with vehicle manufacturers, Tier 1 suppliers, and fleet operators, and is collaborating in the commercial truck and high-end electric vehicle sectors. It is anticipated that the technology will see deployment in electric and hybrid vehicle platforms within the next three to five years.