A TEMPERATURE REGULATED TRAY

Abstract

A tray (1) for releasably engaging a trolley, the tray (1) comprises a body (2) describing a sealed volume (V), the sealed volume (V) having a phase change material (PCM) received therein, the tray (1) comprising an engagement means (4) for releasably engaging a trolley.

Claims

1. A tray for releasably engaging a trolley, the tray comprising a body describing a sealed volume, the sealed volume having a phase change material received therein, the tray comprising a first part of an engager for releasably engaging a second part of an engager located on a trolley.

2. A tray according to claim 1, wherein the phase change material has a phase change temperature of less than zero degrees Celsius.

3. A tray according to claim 1, wherein an insulative foam is located within the sealed volume.

4-5. (canceled)

6. A tray according to claim 3, wherein the insulative foam is an open celled foam or a phenolic foam.

7. (canceled)

8. A tray according to claim 3, wherein the insulative foam has first thermal conductivity and comprises a thermally conductive member having a second thermal conductivity, the first thermal conductivity being less than the second thermal conductivity.

9. A tray according to claim 3, wherein the thermally conductive member comprises one or more of metal, carbon nanotubes and/or graphene.

10. A tray according to claim 9, wherein the insulative foam comprises from 1 to 2% carbon nanotubes and/or graphene by weight.

11. A tray according to claim 1, wherein the body comprises a polymeric material.

12. (canceled)

13. A tray according to claim 1, wherein the body comprises one or more of metal, carbon nanotubes and/or graphene.

14. A tray according to claim 13, wherein the body comprises from 1 to 2% carbon nanotubes and/or graphene by weight.

15. A tray according to claim 1, wherein the body comprises a metallic structure having a coating of a polymeric material.

16. A tray according to claim 1, wherein the body comprises a hydrophobic coating.

17. A tray according to claim 1, comprising an inlet configured to allow for fluid communication with the sealed volume.

18. A tray according to claim 1, wherein the first part of the engager comprises one or more tabs or clips for engaging the second part of the engager located on a trolley.

19. (canceled)

20. A tray according to claim 1, comprising communication means.

21. A tray according to claim 20, wherein the communication means comprises a RFID tag, arranged to contain operational information associated with the tray.

22. A tray according to claim 1, comprising an elastomeric cover arranged to at least partially encapsulate the body.

23. A tray according to claim 1, wherein the body has a first major surface and a second major surface and wherein one of the first major surface and the second major surface is more thermally conductive than the other of the first major surface and the second major surface.

24. (canceled)

25. A galley trolley for an aircraft, comprising a tray according to claim 1.

26. A galley trolley according to claim 25, the trolley comprising a food storage compartment and a tray storage compartment in which the tray is releasably located or locatable by engaging the first part of the engager on the tray with the second part of the engager on the trolley.

Description

[0099] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

[0100] FIG. 1 is perspective view of a tray according to an embodiment of the invention;

[0101] FIG. 2 is an end perspective view of the tray of FIG. 1;

[0102] FIG. 3 is an exploded perspective view of the retainer or retaining means of the tray of FIGS. 1 and 2;

[0103] FIG. 4 is an exploded bottom perspective view of the retainer or retaining means of the tray of FIGS. 1 to 3;

[0104] FIG. 5 is a perspective view of a tray according to an embodiment of the invention;

[0105] FIG. 6 is an exploded perspective view of the tray of FIG. 5;

[0106] FIG. 7 is an exploded perspective view of the retainer or retaining means of the tray of FIGS. 5 and 6;

[0107] FIG. 8a is an exploded perspective view of the tray of FIGS. 5 to 7;

[0108] FIG. 8b is a cross-sectional view of the interface between the first part and second part of FIGS. 5 to 8a;

[0109] FIG. 9 is a perspective view of a tray according to an embodiment of the invention;

[0110] FIG. 10 is an exploded perspective view of the retainer or retaining means of the tray of FIG. 9;

[0111] FIG. 11 is a sectional view of the tray of FIGS. 9 and 10;

[0112] FIG. 12 is an exploded perspective view of the tray of FIG. 9;

[0113] FIG. 13 is a cross-sectional view of the interface between the first part and second part of FIGS. 9 to 12; and

[0114] FIG. 14 is a graph showing the results of the Examples.

[0115] Referring now to FIGS. 1 and 2, there is shown a tray 1 according to an embodiment of the invention, for use in a galley trolley of an aircraft (not shown). The tray 1 has a blow moulded body 2 (hereinafter “body”) describing a sealed volume V arranged to receive a phase change material (PCM). The body 2 is formed of a plastics material as a single part in this embodiment.

[0116] The body 2 is substantially cuboidal, having an upper surface 20, an opposed, lower surface 21, a pair of sidewalls 23, 24, front wall 25 and rear wall 26. The upper surface 20 has optional indicia formed thereon and a peripheral lip 22 extending thereabout. The lower surface 21 is substantially planar in this embodiment (shown more clearly in FIG. 4).

[0117] The pair of sidewalls 23, 24, front wall 25 and rear wall 26 together extend about the body 2 through thickness ‘t’ described between the upper and lower surfaces 20, 21.

[0118] A gripping portion 3 is described by an extension of the body 2, proximate the front wall 25. The gripping portion 3 has a recess 30 extending width-wise along a portion of the front wall 25 so as to describe a handle. A pair of shoulders 31 extend between the gripping portion 3 and the front wall 25.

[0119] A retaining means in the form of a retractable latch 4 is located within recess 40 formed into the upper surface 20, proximate the front wall 25 of the body 2. The retractable latch 4 is configured to retain the tray 1 within a trolley, in use. The recess 40 is of a greater depth than, and is located centrally of, recess 30.

[0120] A recessed portion 27 is located on the rear wall 26, through which an inlet 5 extends. The inlet 5 provides fluid communication with the volume V to allow filling thereof. The inlet 5 is sealed using a cap 50 in this embodiment.

[0121] Referring now to FIGS. 3 and 4, there shown an exploded view of the retractable latch 4. In the present embodiment, the retractable latch 4 has a resilient biaser, in this case a spring 4a, received within the recess 40. Received above the spring 4a is a latch component 4b, which is retained within the recess 40 by cover moulding 4c.

[0122] The spring 4a is formed of sheet metal in this embodiment and has a base plate 40a having a pair of apertures 41a extending therethrough, for receipt of retaining screws R. Each of the apertures 41a extend through frustoconical protrusions 42a that extend from the base plate 40a. Located centrally of the apertures 41a is a tongue 43a. The tongue 43a is connected to the base plate 40a at one end thereof and deformed relative thereto so as to provide a biasing force to latch component 4b.

[0123] The latch component 4b is an injection-moulded plastics component in this embodiment having a latching element 40b formed integrally with actuating element 41b via a connecting member 42b. The latching element 40b and actuating element 41b describe a slot therebetween. The actuating element 41b is arranged such that when it is pressed by a user, the tongue 43a is deformed and both the latching element 40b and actuating element 41b are displaced to allow release of the tray 1 from a trolley (not shown).

[0124] The cover moulding 4c is configured to be received within the recess 40 and has a pair of apertures 40c (of which only one is shown) that are arranged, in use, to be aligned with apertures 41a of the spring component 4a. The cover moulding 4c also has a further pair of apertures 41c arranged to receive a respective one of latching element 40b and actuating element 41b.

[0125] As shown more clearly in FIG. 4, a recess 45 is formed on the lower surface 21, opposite to that of recess 40. A floor portion 46 extends between recess 40 and recess 45, having apertures 47 extending therethrough. The floor portion 46 is described by a portion of the upper surface 20 and a portion of the lower surface 21 adjacent one another, so as to provide a solid area to drill apertures 47. Apertures 41a, 40c and 47 are configured to align such that retaining screws R can extend therethrough and retain the latch 4 within the tray 1, and in particular recess 40.

[0126] When assembling the latch 4, the spring component 4a is positioned within the recess 40 such that apertures 41a and 47 are aligned. The latch component 4b is inserted into the recess 40 above the spring component 4a and the cover moulding 4c is inserted above the latch component 4b such that apertures 40c are aligned with apertures 41a and 47.

[0127] The retaining screws R are inserted through the apertures 40c, 41a and 47 from the lower surface 21 of the tray 1 to retain the latch 4 within the recess 40. Each of the latching element 40b and actuating element 41b are resiliently biased by the tongue 43a, allowing for displacement under the application of force.

[0128] Also shown on the lower surface 21 are a pair of shut-off features 8, located either side of recess 41. The shut-off features 8 are formed by bringing a portion of the upper surface 20 and a portion of the lower surface 21 into contact, so as to provide a degree of reinforcement to the body 2. In the present embodiment, the shut-off features 8 are located in the region of recess 30.

[0129] Referring now to FIGS. 5 and 6, there is shown a tray 101 according to another embodiment of the invention, for use in a galley trolley of an aircraft (not shown). Like features to those of FIGS. 1 to 4 are denoted by like references, incremented by ‘100’.

[0130] The tray 101 has a two-part injection moulded body 102 (hereinafter “body”) describing a sealed volume V arranged to receive a phase change material PCM in the form of a cuboidal block (FIG. 6). The body 102 is formed of a plastics material and includes a first part 102a and a second part 102b that together describe the sealed volume V.

[0131] In the present embodiment, the first part 102a is a tray assembly and the second part 102b is a lid arranged to combine with the first part 102a, and be sealably secured thereto, so as describe the sealed volume V.

[0132] As is the case of tray 1, the body 102 is substantially cuboidal, having an upper surface 120 described by the first part 102a. The body 102 also has an opposed, lower surface 121, a pair of sidewalls 123, 124 a front wall 125 and rear wall 126 each described by the second part 102b. The second part 102b has optional indicia formed thereon and a peripheral lip 122 extending thereabout.

[0133] The pair of sidewalls 123, 124, front wall 125 and rear wall 126 together extend about the body 102 through the thickness ‘t’ described between the upper and lower surfaces 120, 121.

[0134] The first part 102a includes a cavity 106 for receipt of the PCM. The cavity 106 is described by the lower surface 121, sidewalls 123, 124, front wall 125 and rear wall 126.

[0135] A gripping portion 103 is formed integrally with the first part 102a, proximate the front wall 125. The gripping portion 103 has a recess 130 extending widthwise along a portion of the front wall 125 so as to describe a handle. A pair of shoulders 131 extend between the gripping portion 103 and the front wall 125.

[0136] The gripping portion 103 also has a pair of apertures 132, 133 extending therethrough for receiving a retaining means in the form of a retractable latch 104. The pair of apertures 132, 133 are separated by a wall 134 having a pair of recesses in this embodiment (not shown) for receipt of retaining screws R. The wall 134 provides a mounting point for the latch 104. A portion of the latch 104 protrudes from the upper surface 120 and is configured to retain the tray 101 within a trolley (not shown), in use.

[0137] As shown in greater detail in FIGS. 6 and 7, the latch 104 has a spring component 104a arranged to be affixed to the lower surface 121 of the body 102 via retaining screws R. Received above the spring 104a is a latch component 104b, which itself extends through the apertures 132, 133.

[0138] The spring 104a is formed of sheet metal in this embodiment and has a base plate 140a having a pair of apertures 141a extending therethrough, for receipt of retaining screws R. Each of the apertures 141a extend through frustoconical protrusions 142a that extend from the base plate 140a. Located centrally of the apertures 141a is a tongue 143a. The tongue 143a is connected to the base plate 140a at one end thereof and deformed relative thereto so as to provide a biasing force to latch component 104b.

[0139] The latch component 104b is a moulded plastics component in this embodiment having a latching element 140b formed integrally with an actuating element 141b via a connecting member 142b. The latching element 140b and actuating element 141b describe a slot therebetween. The actuating element 141b is arranged such that when pressed by a user, the tongue 143a is deformed and both the latching element 140b and actuating element 141b are displaced. The connecting member 142b has a pair of recesses 144b for receipt of a respective retaining screw R during assembly.

[0140] As shown in FIG. 7, in order to assemble the latch 104 the latching element 140b is received within a first of the pair of apertures 132 and the actuating element 141b is received within the other of the apertures 133. The connecting member 142b abuts the wall 134 and the spring component 104a is brought adjacent the lower surface 121 such that the connecting member 142b lies between the wall 134 and a portion of the spring component 104b. The apertures 141a are aligned with the recess of wall 134 and recesses 144b and the retaining screws R are passed therethrough so as to retain the latch component 104b on the tray 101 via the spring component 104a.

[0141] Referring now to FIGS. 8a and 8b, there is shown the assembly of the first part 102a and second part 102b so as to describe the sealed volume V. As shown in more detail in FIG. 8b, each of the first part 102a and second part 102b have a respective ledge 128, 129. Ledge 128 extends about the periphery of the cavity 106 and ledge 129 extends about the periphery of the second part 102b. Each respective ledge 128, 129 includes a step portion 128a, 129a. Each respective ledge 128, 129 also includes a wall 128b, 129b extending therefrom and between the gripping portion 103 and cavity 106. The walls 128b, 129b each have a corresponding taper to provide a lead-in when mounting the second part 102b to the first part 102a. Ledges 128 and 129 are configured to provide an interface between the first part 102a and second part 102b.

[0142] During assembly of the tray 101 in the present embodiment, a foam pad FP is received within the cavity 106. The first part 102a is brought adjacent the second part 102b such that ledges 128 and 129 are in contact. In the present embodiment, the interface between the ledges 128, 129 is heated so as to fuse the first part 102a to the second part 102b, creating the sealed volume V. Before the first part 102a and second part 102b are sealed together, a fluid PCM material is poured onto the foam pad FP. The foam pad FP acts as a matrix for the PCM and reduces the effective volume of the internal volume of the tray.

[0143] In embodiments of the invention we prefer a polyurethane or a phenolic foam material for the foam pad FP.

[0144] Referring now to FIGS. 9 and 10, there is shown a tray 201 according to an embodiment of the invention, for use in a galley trolley of an aircraft (not shown). Where appropriate, like features to those of FIGS. 1 to 4 are denoted by like references, incremented by ‘200’.

[0145] The tray 201 has a two-part body 202 formed from a combination of blow-moulding and injection moulding and describing a sealed volume V arranged to receive a phase change material PCM in the form of a cuboidal block (FIG. 12). The body 202 is formed of a plastics material and includes a first part 202a and a second part 202b that together describe the sealed volume V.

[0146] In the present embodiment, the first part 202a is a blow moulded sleeve assembly and the second part 202b is an injection moulded cap arranged to be combine with the first part 202a, and be sealably secured thereto, so as describe the sealed volume V.

[0147] As is the case of tray 1, the body 202 is substantially cuboidal. The first part 202a has an upper surface 220, an opposed, lower surface 221, a pair of sidewalls 223, 224 and a rear wall 226 together describing a sleeve forming a cavity 206 having an opening O (FIG. 11). The cavity 206 is configured to receive a foam pad FB and the PCM (FIG. 12).

[0148] The body 202 also has a front wall 225 described by the second part 202b. Each of the front wall 225 and rear wall 226 are widthwise extending. The first part 202a has indicia formed on the upper surface 220 thereof.

[0149] The pair of sidewalls 223, 224, front wall 225 and rear wall 226 together extend about the body 202 through the thickness ‘t’ described between the upper and lower surfaces 220, 221.

[0150] A gripping portion 203 is formed integrally with the second part 202b, proximate the front wall 225. The gripping portion 203 has a recess 230 extending widthwise along a portion of the front wall 225 so as to describe a handle. A pair of shoulders 231 extend between the gripping portion 203 and the front wall 225.

[0151] The gripping portion 203 also has a pair of apertures 232, 233 extending therethrough for receiving a retaining means in the form of a retractable latch 204. The pair of apertures 232, 233 are separated by a wall 234 having one or more recesses in this embodiment (FIG. 11) for receipt of retaining screws R. The wall 234 provides a mounting point for the latch 204. The latch 204 protrudes from the second part 202b and is configured to retain the tray 201 within a trolley (not shown), in use.

[0152] As shown in greater detail in FIGS. 10 and 11, the latch 204 has a spring component 204a arranged to be affixed to the lower surface 221 of the body 202, in particular to the second part 202b, via retaining screws R. Received above the spring component 204a is a latch component 204b, which itself extends through the apertures 232, 233.

[0153] The spring component 204a is formed of sheet metal in this embodiment and has a base plate 240a having a pair of apertures 241a extending therethrough, for receipt of retaining screws R. Each of the apertures 241a extend through frustoconical protrusions 242a that extend from the base plate 240a. Located centrally of the apertures 241a is a tongue 243a. The tongue 243a is connected to the base plate 240a at one end thereof and deformed relative thereto so as to provide a biasing force to latch component 204b.

[0154] The latch component 204b is a moulded plastics component in this embodiment having a latching element 240b connected to an actuating element 241b via a connecting member 242b. The latching element 240b and actuating element 241b describe a slot therebetween. The actuating element 241b is arranged such that when it is pressed by a user, the tongue 243a is deformed and both the latching element 240b and actuating element 241b are displaced. The connecting member 242b has a pair of recesses 244b for receipt of a respective retaining screw R during assembly.

[0155] In order to assemble the latch 204 the latching element 240b is received within a first of the pair of apertures 232 and the actuating element 241b is received within the other of the apertures 233. The connecting member 242b abuts the wall 234 and the spring component 204a is brought adjacent the lower surface 221 of the second part 202b such that the connecting member 242b lies between the wall 234 and a portion of the spring component 204a. The apertures 241a are aligned with the recess of wall 234 and recesses 244b and the retaining screws R are passed therethrough so as to retain the latch component 204b on the tray 201 via the spring component 204a.

[0156] Referring now to FIGS. 11 to 13, there is shown the assembly of the first part 202a and second part 202b so as to describe the sealed volume V. As is shown, the first part 202a has a ledge 227 extending about the opening O and a wall 227b inboard of, and extending therefrom. Inboard in this sense will be understood to be towards the central of the opening O. The second part 202b also has a peripheral wall 229 extending from the front wall 225 towards a free end 229a.

[0157] During assembly of the tray 201, the foam pad FP is received within the cavity 206. The first part 202a is brought adjacent the second part 202b such that the wall 227b lies inboard of, and adjacent, the peripheral wall 229 and the free end 229a is brought into contact with ledge 227. Before the first part 202a and second part 202b are secured together a fluid PCM material is poured into the internal volume of the tray.

[0158] In the present embodiment, the interface between the walls 227b and 229 is heated so as to fuse the first part 202a to the second part 202b, creating the sealed volume V.

[0159] In order to assess the performance of PCM materials against the currently in-use dry ice (CO.sub.2 (s)) coolant the following experiments were conducted.

COMPARATIVE EXAMPLE 1

[0160] 2.4 kg of dry ice was loaded into a tray with dimensions 315×270×27 mm and located at the top of a galley trolley which was loaded with food. [0161] The core temperature of the food was measured over time. [0162] The results are shown in FIG. 14.

EXAMPLE 1

[0163] Into an identical tray to that used in Comparative Example 1, a block of foam (282×224×25 mm) and 2 litres of a phase change material with a phase change temperature of −50° C. was loaded. The tray was loaded into an identical galley trolley stocked with the same foodstuffs as per Comparative Example 1. [0164] The core temperature of the food was measured over time. [0165] The results are shown in FIG. 14.

EXAMPLE 2

[0166] Example 1 was repeated but the 2 litres of phase change material was replaced with 1.4 litres of the PCM and 0.9 litres of water. [0167] The results are shown in FIG. 14.

EXAMPLE 3

[0168] Example 1 was repeated but the phase change material was replaced with 2 litres of a phase change material having a phase change temperature of −7° C. [0169] The results are shown in FIG. 14.

[0170] The experiments demonstrate that PCM materials are able to maintain the core temperature of the food below 10° C. over extended time periods.

[0171] Indeed, all of the Examples of the invention outperform dry ice over a 5 hour window and Example 2 outperforms dry ice after two hours, whilst Example 1 out performs dry ice after four hours. The result of Example 2 is surprising because it has less PCM than Example 1 and so would be expected to perform less well.

[0172] Clearly, all of the Examples of the invention are able to maintain a low temperature of food and, critically, are able to ensure low temperatures over a long time period, which becomes important in case of delays.

[0173] Notwithstanding, the improved performance, the use of PCM materials provides extra flexibility to users, reduces supply chain issues and reduces handling problems associated with dry ice.

[0174] It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention. For example, any of the features described in relation to tray 1 may be applied or interchanged with any of the features described in relation to tray 101 or tray 201, where such features are compatible. Further, whilst the interface between the ledges 128, 129 of tray 101 and between walls 227b and 229 of tray 201 is heated so as to fuse the respective first and second parts together, creating the sealed volume V, this need not be the case.

[0175] Instead, any other suitable means for connecting the first and second parts together so as to create a fluid tight seal may be utilised, e.g. a snap fit arrangement, the incorporation of one or more gaskets and/or the use of a sealing agent between the first and second parts. It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and/or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

[0176] Also, the walls of the container may have different thicknesses to each other. For example, an intended bottom most surface (e.g. lowermost surface 21) may be thinner than the intended uppermost surface (e.g. uppermost surface 20) and the side walls (e.g. walls 23-26). In this way the lowermost surface will be more thermally conductive and heat will flow into that wall in a greater flux than it will flow into the other walls. Of course, in addition or instead, the lowermost wall may be made from, or comprise, a material which has a higher thermal conductivity than the other walls.

[0177] Each tray may comprise thermal conductivity promoters. For example, the intended comestible-facing side or face of the tray may comprise thermal conductivity promoters. These may be in the form of protuberances, fins etc which extend from a surface of the tray into the sealed volume. In an embodiment these may be formed on the internal surface of the tray, for example by joining or integrally forming.

[0178] The provision of a pattern or other indicator on the intended uppermost surface may provide a convenient visual indicator to allow an operative to install the tray in the correct orientation. The tray may be shaped

[0179] Further, it is also possible to provide the tray with a liner material to line all or some of the internal walls thereof. The tray can be made from metal materials, for example aluminium or aluminium alloys. A metal liner material may aid or encourage heat conduction in a desired direction. The liner may be made from polymeric or plastics materials. A polymeric or plastics liner material may inhibit heat conduction in a desired directions. The polymeric material or plastics liner material may be doped with heat conductive materials. A doped polymeric/plastics liner may aid or encourage heat conduction in a desired direction.

[0180] The tray may also be provided with a hydrophobic coating.