FLATBED TRAILER DE-ICING SYSTEMS

Abstract

A system for preventing the formation of ice or removing ice from an undercarriage or roof of an automotive vehicle such as a truck or a trailer. The system comprises a combination of a network of a plurality of conductive heating elements. The system can be implemented on the undercarriage or roof without altering the configuration of the undercarriage or roof by attaching the system to a deck and cross beams of the undercarriage or roof. The system is powered by an auxiliary power unit and controlled by a thermostatic controller.

Claims

1. A de-icing system, wherein the system comprises: a surface of an automobile undercarriage or an automobile roof; an auxiliary power unit; a thermostatic controller; a switch unit coupled to the auxiliary power unit and the thermostatic controller; an electrical system, the electrical system comprising a plurality of conductive heating elements coupled to the auxiliary power unit and thermostatic controller, wherein the plurality of conductive heating elements are linked to each other via a heating relay system of heat conductive wire, wherein the conductive heating elements are arranged in a pattern; and a plurality of heat sensors placed along electrical heat sensor wiring; wherein the heat conductive wire and the electrical heat sensor wiring are encapsulated by a rubber insulation layer.

2. The de-icing system of claim 1, wherein the plurality of conductive heating elements comprise silicone heaters and built-in thermal conductive adhesive.

3. The de-icing system of claim 2, wherein the silicone heaters comprise at least one of a thermostat, a resistance temperature detector, a thermocouple, and a thermal fuse.

4. The de-icing system of claim 2, wherein the silicone heaters are a wire-wound style or flexible silicone heaters.

5. The de-icing system of claim 1, wherein the thickness of each of the plurality of conductive heating elements is in a range of 0.0056-0.022 inches.

6. The de-icing system of claim 2, wherein the thermal conductive adhesive has a continuous operating temperature up to 180 degrees Fahrenheit.

7. The de-icing system of claim 1, wherein the auxiliary power unit provides voltage in a range of 6 to 240 volts.

8. The de-icing system of claim 7, wherein the voltage is provided in a form of alternating current, wherein a phase of the voltage is either single or three-phase.

9. The de-icing system of claim 7, wherein the voltage is provided in a form of direct current.

10. The de-icing system of claim 2, wherein an insulator is added to one side of each of the silicone heaters, wherein the insulator is selected from at least one of aluminum and silicone.

11. The de-icing system of claim 1, wherein the plurality of conductive heating elements are polyimide heaters, the polyimide heaters comprising a thin etched foil circuit laminated between two lightweight polyimide films.

12. The de-icing system of claim 1, wherein the plurality of conductive heating elements are in a number from 12 to 20.

13. The de-icing system of claim 1, further comprising a thermostatic gauge connected to the thermostatic controller.

14. The de-icing system of claim 1, wherein a temperature of the surface is maintained between 75 and 110 degrees Fahrenheit.

15. The de-icing system of claim 1, wherein the pattern comprises a plurality of rows and a plurality of columns.

16. The de-icing system of claim 1, wherein spacing distances between each of the conductive heating elements are the same in any of the rows or the columns, or spacing distances between some or all of the conductive heating elements are different in any of the rows or the columns.

17. The de-icing system of claim 1, wherein the conductive heating elements are arranged external to an insulation layer, and the insulation layer is arranged external to an exterior roof.

18. The de-icing system of claim 1, wherein the conductive heating elements are arranged between an exterior roof and an interior roof, wherein an insulation layer is arranged between the conductive heating elements and the interior roof.

19. The de-icing system of claim 1, wherein the heat sensors are spaced along a length of the surface of the automobile undercarriage or the automobile roof with a distance of 1.33 inches between each of the heat sensors.

20. The de-icing system of claim 19, wherein the heat sensors are spaced along a width of the surface of the automobile undercarriage or automobile roof with a distance of 10.5 inches between each of the heat sensors.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0041] FIG. 1 shows a representative schematic view of an undercarriage of an automobile with the electrical system.

[0042] FIG. 2 shows an arrangement of the conductive heating elements along the surface of the automobile undercarriage.

[0043] FIG. 3 depicts an example surface of an automobile undercarriage with cross beams.

[0044] FIGS. 4A-4B provides examples of conductive heating elements for achieving the invention, with FIG. 4A depicting examples of heaters for the conductive heating elements and FIG. 4B depicting heaters of various shapes.

[0045] FIGS. 5A and 5B provide additional embodiments of the installation of the electrical system. FIG. 5A depicts an external application and FIG. 5B depicts an internal application of the heating elements arranged with an insulation layer.

[0046] FIG. 6 depicts a cross section of the wiring system.

[0047] FIG. 7 depicts an example electrical power adapter for coupling the system to an APU connection and commercial generator connection.

[0048] The drawings do not need to be necessarily scaled and the details that are not required for understanding the present invention may be overlooked. In addition to that, the elements that are identical at least in a large extent or which have functions that are identical at least in a large extent are represented with the same number.

DESCRIPTION OF THE PART REFERENCES

[0049] 1. Surface of an automobile undercarriage or automobile roof [0050] 2. Heat conductive wiring [0051] 3. Conductive heating elements [0052] 4. Auxiliary power unit (APU) [0053] 5. Thermostatic controller [0054] 6. Switch unit [0055] 12. Heat sensors [0056] 13. Thermostatic gauge [0057] 14. Pigtail wire connection [0058] 16. Heat sensor wiring [0059] 17. APU connection and commercial generator connection [0060] 18. Cross beam [0061] 19. Electrical power adapter [0062] 20. Insulation layer [0063] 21. Exterior roof [0064] 22. Interior roof [0065] 23. Rubber insulation layer [0066] 24. Apron [0067] 25. Commercial standalone generator

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0068] The system is to de-ice the trailer deck using an electrical system of conductive heating elements, which comprise at least one of a thermostat, a resistance temperature detector, a thermocouple, and a thermal fuse. The system will sufficiently prevent and/or melt the ice on the trailer bed and keep cargo from freezing to the deck, where the deck is made from any material such as metal, alloys, composites, aluminum, steel, and any other material which functions as a deck. The scope of this invention defines de-icing as preventing the formation of snow and/or ice buildup as well as remove ice and/or snow and on any surface of a vehicle.

[0069] The electrical system depicted in FIG. 1 utilizes preferably between 12 and 20 conductive heating elements 3 linked to each other via a heating relay system around the surface of an automobile undercarriage or automobile roof 1 attached to the bottom of the aluminum deck, though less than 12 or greater than 20 conductive heating elements can certainly be used. Heat conductive wiring 2 is attached to each conductive heating element 3. Testing must be done to determine which size of the conductive heating elements 3, such as thermocouplers, work best. The objective is to heat the surface of the automobile undercarriage or automobile roof 1 to a temperature between 75 to 110 degrees thus keeping ice from being able to form and or melting existing ice on the deck. This heating scale should prevent thermal injury to the trailer and to personnel. Existing spare switches within a switch unit 6, configured to be attached on the automobile sleeper berth as per DOT, is implemented to activate and deactivate the system. The de-icing system will be initiated to activate, e.g., current will be supplied to the conductive heating elements 3 while the automobile such as a commercial truck or a passenger vehicle is running or when a switch from switch unit 6 connects the de-icing system to the auxiliary power unit 4. Initiating the de-icing system should be done prior to the driver arriving at the shipper or receiver. The driver should turn on the de-icing system at least 10 hours the night before or after loading or unloading of cargo, and can be done with or without the APU 4 running. Therefore, the de-icing system can be active when or after the driver arrives at the shipper or receiver. Preferably the deck should stay warm for up to two hours with the engine off.

[0070] Heat sensors 12 are placed along heat sensor wiring 16 and are connected to the thermostatic controller 5. The heat sensors 12 are spaced along a length of the surface of the automobile undercarriage or automobile roof 1 with a distance preferably at 1.33 inches between the heat sensors 12, and along a width of the surface of the automobile undercarriage or automobile roof 1 with a distance preferably at 10.5 inches between them. The heat sensors 12 will detect when the temperature reaches a low variant below 75 degrees Fahrenheit, the heat sensors 12 will provide feedback to the thermostatic controller 5, and the thermostatic controller 5 is connected to an alert indicator which will alert the driver, via a noise and/or a light, to initiate the de-icing system again the system. Inside the automobile there will be a thermostatic gauge 13 connected to the thermostatic controller 5 to monitor the temperature of the automobile undercarriage or automobile roof 1 or flatbed. A separate pigtail wire connection 14 will be made for this system to connect between the thermostatic controller 5 on the automobile dashboard to the heating relay system on the undercarriage or roof. This de-icing system will generate heat that will keep the surface of the automobile undercarriage or roof ice free. The spacing distances (measured from an edge/outer surface of the heat sensors 12) between the conductive heating elements 3 and/or the heat sensors 12 can be smaller or larger than the above disclosed 1.33 inches and 10.5 inches, though these metrics have been tested and were unexpectedly found to be most effective and variations would reduce operating efficiency of the ability to heat the surface 1.

[0071] There are several options of conductive heating elements available. First, there are silicone heaters, which are beneficial in that they transfer heat uniformly and rapidly. This is because they are thinly constructed, they heat uniformly, and they are close to the surface to which they are applied. They are rugged and maintain dimensional stability. They resist moisture and chemical degradation and are compatible with flat and curved surfaces. They can be vulcanized in the factory for use on metallic surfaces. Silicone heaters can be constructed with thermostats, resistance temperature detectors (RTD), thermocouples, or thermal fuses, as depicted in FIG. 1. A pressure sensitive thermal conductive adhesive can be used to fasten the heater to a surface which can even activate on exposure to air. Ultimately, in the manufacturing process, heaters can be infused onto an aluminum surface, which is one example of a type of surface of an automobile undercarriage or automobile roof 1. Another type of surface is depicted in FIG. 3, consisting of a plurality of cross beams 18 for attaching the system to the automobile undercarriage such as a vehicle apron.

[0072] Silicone heaters are available in two types: 1) wire-wound style: a specific pattern is created using resistance wiring or etched foil, a flat circuit formed when a resistant foil is etched to a specific pattern; 2) flexible silicone heaters, which when placed can de-ice or prevent the initial ice buildup on the surface of an automobile undercarriage or automobile roof 1 or a flatbed deck. Depending on the conductive heating elements 3, the thickness can range from 0.022-0.0056 inches. Heat is created by resistance to the electric current passing through each conductive heating element 3. Silicone heaters can be custom designed to any size or shape such as circles, rectangles, or any polygon shape or any geometric shape. Examples are depicted in FIGS. 4A-4B. Silicone heaters can have a continuous operating temperature up to about 180 degrees Fahrenheit, far above the actual need. Heat loss can be prevented by adding aluminum or additional silicone insulation to any number of sides or edges that are exposed to the ambient. Silicone is also an excellent insulator. This invention employs temperatures in the 75-110 degrees Fahrenheit range, but will be able to vary the temperature based on the outside ambient temperatures and the time needed to de-ice. Further, the conductive heating elements 3 may also be set overnight to a temperature above freezing, preferably in the 50-70 degree Fahrenheit range, more preferably at 60 degrees Fahrenheit.

[0073] Flexible heaters meet all industry standards: UL, large VDE, large IEC, large NEC, ISO or NFPA standards. Voltage can range from 6 volts to 240 volts, alternating current (AC) or direct current (DC), single or 3 phase. The temperature output is controlled by thermal limiting devices, such as a thermostat, a resistance temperature detector, a thermocouple, or a thermal fuse, wired directly into the heaters and controlled by external temperature controllers. The source of the power is the APU, which can run overnight and generate the necessary heat to prevent ice build-up. This generator may be part of the truck or can be used in the loading areas on a standby basis to plug into the silicone heater layout. As electrical truck technology develops, this system will fit into advancing battery technologies coming in the future.

[0074] Heat sensors 12 are placed along the surface of the automobile undercarriage or automobile roof 1 attached to the heat sensor wiring 16 to ensure safe adequate heating. The wiring 16 will run from the truck's batteries to a pigtail wire connection 14 on the trailer. A switch within switch unit 6 on the automobile dashboard will be used to turn the system on and off.

[0075] Further, a pattern of the conductive heating elements 3 comprises a plurality of rows and a plurality of columns on the surface 1, as depicted in FIG. 2. The conductive heating elements 3 are arranged in an array that are M columns by N rows (M is 3 and N is 4 in FIG. 2) on the surface 1. The spacing distance between each of the conductive heating elements 3 may have the same spacing distance or may have different spacing distances between some or all of the conductive heating elements 3 in any of the rows or columns. Combined, these two systems provide a safer and more stable work environment for drivers when confronted with icy conditions. They will also help save insurance companies millions of dollars in losses. This concept will improve worker efficiency at any loading and unloading site and reduce the risk of workers falling of the trailer.

[0076] FIG. 1 also depicts APU connection and commercial generator connection 17 with connection to commercial standalone generator 25. As displayed, connection 17 is connected to the thermostatic controller 5. This element provides the primary source of power to the electrical system the de-icing system when the automobile is running, and when it is not running, the de-icing system will source its power from the auxiliary power unit 4 by activating a switch in switch unit 6.

[0077] In one embodiment, the electrical system utilizes a specially designed series of silicone heaters affixed via a pressure sensitive thermal conductive adhesive, which is high temperature rated to 180 degrees Fahrenheit, is permanent and all weather. Depending on the size of the automobile such as a commercial truck or a passenger vehicle, 53′, 48′ or 28′, this invention uses a series of 12 to 20 custom designed silicone heaters. Each conductive heating element sized 18″ wide by 82″ long is attached to the automobile, e.g., truck or trailer, roof or undercarriage surface. The conductive heating elements 3 are easily installed with (i.e. due to) the adhesive. Alternative methods of installing or attaching the conductive heating elements 3 are fixing with screws, rivets, brackets, glue, etc., and installation can be done to either the roof or the undercarriage of the automobile. In an example cited below for a 28 foot dry-van, each custom-built conductive heating element is constructed of:

[0078] 1. Flexible silicone heater panel with 2 ply woven glass tech style reinforced silicone rubber;

[0079] 2. Etched foil conductive heating elements for even heating;

[0080] 3. Twelve conductive heating elements, each sized 18″×82″. These will be spaced in three rows of four each to distribute heat uniformly where needed, similar to the embodiment depicted in FIG. 2;

[0081] 4. All weather pressure sensitive thermal conductive adhesive backing;

[0082] 5. 120 volt operation;

[0083] 6. Power is 305 watts per each conductive heating element, 3600 watts total;

[0084] 7. Power leads—72″ long, exit corner of long side; Another source of ice build-up prevention is a ground thaw heating blanket, which can be attached to the surface of the automobile undercarriage or automobile roof 1. These blankets provide higher watt densities, dispensing heat uniformly across the entire surface of the automobile undercarriage or automobile roof 1. When combined with an adjustable or fixed thermostatic controller 5, they can raise temperatures as high as 145 degrees F. and can be used in temperatures as low as −20 degrees F. These are easily installed with grommets or fasteners. Polymide heaters can also be used. They consist of a thin etched foil circuit, laminated between two light weight polymide films that provide high dielectric strength, superior resistance and low outgas characteristics. These can be custom designed distributing wattage heat profiles to the aluminum roof and can be also made with a pressure sensitive thermal conductive adhesive.

[0085] A summary of possible heaters for the conductive heating elements 3 are provided in FIGS. 4A-4B. FIG. 4A depicts etched foil heaters, polyimide or Kapton heaters, preformed heaters, and wire wound heaters as examples that can be implemented within the conductive heating elements 3. The heaters shown can be provided in multiple shapes as well, such as circles, rectangles, or various polygons, provided in FIG. 4B. The conductive heating elements 3 do not require to be placed in grooves to be attached to the surface 1. Instead, as discussed above, the conductive heating elements 3 can be installed through fixing with screws, rivets, brackets, glue, etc., and installation can be done to either the roof or the undercarriage of the automobile. The surfaces of the roof or undercarriage of the automobile can be planar, e.g., flat, or with ridges or grooves as depicted on the apron 24 in FIG. 3, and can be a smooth or rough surface. The surfaces are most likely to be made of aluminum, steel, or composites of various metals.

[0086] FIGS. 5A-5B depicts additional examples of how the electrical system can be arranged on an automobile, specifically external application (FIG. 5A) or internal application (FIG. 5B) embodiments. The external application embodiment provides installation of the electrical system, specifically the conductive heating elements 3, exposed to the environment and external to the automobile by being outside from an exterior roof 21. This embodiment further provides an insulation layer 20 between the conductive heating elements 3 and the exterior roof 21, e.g., the exterior of the automobile has insulation layer 20 mounted to the exterior roof 3, then the conductive heating element 3 is mounted on the insulation layer 20 such that less heat is lost into the automobile and the conductive heating elements 3 only melt snow on the exterior of the automobile. The internal application embodiment provides the conductive heating elements 3 to be installed between the exterior roof 21 and an interior roof 22, wherein the insulation layer 20 is installed between the interior roof 22 and the conductive heating elements 3 such that the conductive heating elements 3 are in contact with the interior surface of the exterior roof 21 of the automobile. This would enable the insulation layer 20 to separate the conductive heating elements 3 from the rest of the interior of the automobile to further prevent heat loss.

[0087] FIG. 6 depicts a cross-section and further details regarding the wiring system of the invention. Specifically, all wiring is encapsulated by a rubber insulation layer 23, the rubber insulation layer 23 being a closed layer, approved by the DOT. One example of such a rubber insulation layer 23 is the K-FLEX® INSUL-SHEET®, which is a polyvinyl chloride (PVC) resin blended with nitrile polymers (NBR), or an NBR/PVC based closed cell, flexible elastomeric foam insulation, though similar or equivalent materials may be used. This rubber insulation layer 23 will cover all wiring between the conductive heating elements 3 and all wiring from the surface of an automobile undercarriage or automobile roof 1 down an apron of all types of automobiles. The rubber insulation layer 23 solves the problem of keeping condensation off of all wiring as well as the surface of an automobile undercarriage or automobile roof 1, which subsequently prevents the wiring from freezing over. The rubber insulation layer 23 also prevents sparks from the wiring and potential risks of fire that could result. This rubber insulation layer 23 will be applied to the heat conductive wiring 2, the pigtail wire connection 14 and the heat sensor wiring 16.

[0088] These systems are adaptable to many platforms such as flatbed railcars, container trailers, and lowboy trailers through the use of an electrical power adapter 19 for coupling the system to an APU connection and commercial generator connection 17, such as the example provided in FIG. 7. Some examples of the electrical power adapter 19 or additional adapters are an ITT Cannon™ CA3106E18 plug, a Philips Stay Dry SAE J560, or a Tramec Sloan J560 plug. These adapters can be mounted on a side of the automobile, more specifically an apron of the automobile. The adapter can also be used to connect to the auxiliary power unit 4, one example of which can be a Dynasys™ generation III auxiliary power unit. The auxiliary power unit 4 may be mounted on a frame of the automobile and may be used when the driver of the automobile is in compliance with hours of the service rules. The adapter may also be able to connect to a generator, such as a Kubota™ GL Series 7000 generator, thus enabling the automobile to be connected to an additional external power supply when stationary during rest hours.

[0089] In conclusion we have proven the need for the concepts and how it will help ground transportation overall. Having the ability to help more than one platform helps to seek the DOT's safety mandate. These de-icing concepts will save time and money for everyone involved in the flatbed transportation sector.

[0090] The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.