Method and apparatus for detecting ice accretion

1. A method of determining ice accretion on a surface of an aircraft, the method comprising:

supplying a known power to a heating element included within a heat generating layer, wherein the heating element and a sensor are integrally formed in a layered patch including a thermally conductive layer that forms a surface of the aircraft and has a contour consistent with a surface surrounding the layered patch such that the layered patch is aerodynamically consistent with the surface of the aircraft, the layered patch further including a sensor layer located between the thermally conductive layer and the heat generating layer, the sensor layer further including a first sensor layer and a second sensor layer with the sensor is disposed in-between the first sensor layer and the second sensor layer;

determining, in a controller module, when the heating element has satisfied at least one temperature threshold;

altering the supplying of known power to the heating element when it is determined that the heating element has satisfied the at least one temperature threshold;

sensing, via the sensor, a thermal signature of the heating element to define a sensed thermal signature;

comparing, in a controller module, the sensed thermal signature with a threshold signature;

determining, in the controller module, if the sensed thermal signature satisfies the threshold signature;

indicating, by the controller module, that ice accretion has been determined when the controller module determines that the sensed thermal signature satisfies the threshold signature; and

altering operation of an aircraft system based on the indication.

2. The method of claim 1 wherein the comparing includes comparing a rate of change of the sensed thermal signature with a rate of change of the threshold signature.

3. The method of claim 1 , wherein the comparing further comprises repeatedly comparing the sensed thermal signature with the threshold signature.

4. The method of claim 1 wherein the supplying includes supplying of power until the heating element has satisfied both a first and second temperature threshold.

5. The method of claim 1 wherein indicating includes providing indication on a display within the aircraft.

6. The method of claim 1 wherein the indicating includes providing the altered operation of the system in the form of a flight plan modification, and wherein the altering includes modifying a flight plan.

7. The method of claim 1 wherein the indicating further includes providing indication to a de-icing system, and wherein the altering includes automatically operating the de-icing system in response to the indicating.

8. The method of claim 1 wherein the layered patch further includes at least one insulating layer.

9. The method of claim 8 wherein the layered patch comprises multiple insulating layers, with at least one of the multiple insulating layers comprising an electro-thermal insulating layer.

10. The method of claim 1 wherein the layered patch further includes an electro-thermal insulation layer having a first side adjacent a portion of the aircraft, the heat generating layer incorporating the heating element adjacent a second side of the electro-thermal insulation layer, and an electrical insulation layer adjacent the heating element, the sensor being located adjacent to the electrical insulation layer or within the electrical insulation layer.

11. The method of claim 10 wherein the thermally conductive layer of the layered patch is adjacent the electrical insulation layer.

12. A system for determining ice accretion on a portion of an aircraft, the system comprising:

a layered patch including a thermally conductive layer that forms a surface of the aircraft and has a contour consistent with a surface surrounding the layered patch such that the layered patch is aerodynamically consistent with the surface of the aircraft, the layered patch comprising:

a heat generating layer that operates in thermal cycles defined by a first period of time when the heat generating layer generates heat while energized, and by a second period of time when the heat generating layer does not generate heat while not energized;

a sensor layer located between the heat generating layer and the thermally conductive layer, the sensor layer including a first sensor layer coupled to the heat generating layer, a second sensor layer coupled to the first sensor layer, and a sensor that is disposed in-between the first sensor layer and the second sensor layer, the sensor layer being adapted to sense a thermal cycle indicative of ice accretion at a location of the layered patch;

a controller module configured to compare the sensed thermal cycle with a threshold thermal cycle, determine if the sensed thermal cycle satisfies the threshold thermal cycle, and indicate that conditions favorable for icing exist when the sensed thermal cycle satisfies the threshold thermal cycle.

13. The system of claim 12 wherein the system further comprises multiple layered patches operably coupled to the controller module.

14. The system of claim 12 wherein the portion of the aircraft is one of a wing or inlet duct of an engine.

15. The system of claim 12 wherein the controller module is further configured to at least one of provide an indication that ice accretion has been determined or alter operation of a system within the aircraft.

16. The system of claim 12 wherein the layered patch further includes at least one insulating layer.

17. The system of claim 16 wherein the at least one insulating layer is an electro-thermal insulating layer.

18. The system of claim 12 wherein the layered patch includes an electro-thermal insulation layer having a first side adjacent a portion of the aircraft, a heat generating layer incorporating a heating element adjacent a second side of the electro-thermal insulation layer, an electrical insulation layer adjacent the heating element, the sensor being located adjacent to the electrical insulation layer or within the electrical insulation layer, and a thermally conductive layer adjacent the electrical insulation layer and forming the surface of the aircraft.