Aircraft galley carts and associated methods of manufacture
Aircraft galley carts and methods for their manufacture are disclosed herein. In one embodiment, a galley cart for use on an aircraft includes a body configured to be moved along a passenger aisle of the aircraft. The body can include a one-piece plastic shell forming a first side portion and at least one of a second side portion, a top portion, and a bottom portion of the body. In one aspect of this embodiment, at least a portion of the one-piece plastic shell can include an inner skin offset from an outer skin in a double-wall configuration.
1. A galley cart for use on an aircraft, the galley cart comprising:
a body configured to be moved along a passenger aisle of the aircraft, the body including a one-piece plastic shell, wherein the one-piece plastic shell includes an inner skin, an outer skin offset from the inner skin in a double-wall configuration, and a foam core positioned between the inner and outer skins, wherein the inner skin, the outer skin and the foam core are formed from the same material, and wherein the one-piece plastic shell forms:
a first side portion of the body;
a second side portion of the body;
a top portion of the body;
a bottom portion of the body, wherein the first side portion is spaced apart from the second side portion, wherein the top portion extends between the first and second side portions, and wherein the bottom portion is spaced apart from the top portion and extends between the first and second side portions; and
at least one horizontal shelf extending from the first side portion to the second side portion between the top and bottom portions;
at least one threaded insert molded into the one-piece plastic shell;
a door;
a hinge attached to the door; and
at least one threaded fastener engaging the threaded insert and attaching the hinge to the one-piece plastic shell to pivotally attach the door to the body.
2. The galley cart of claim 1 wherein the one-piece plastic shell includes an injection molded portion.
3. The galley cart of claim 1 wherein the one-piece plastic shell includes a rotational molded portion.
4. The galley cart of claim 1 wherein at least a portion of the door includes an inner door skin offset from an outer door skin in a double-wall configuration.
5. The galley cart of claim 1 wherein at least a portion of the door includes an inner door skin offset from an outer door skin in a double-wall configuration, and wherein the door further includes core material positioned between the inner and outer door skins.
6. The galley cart of claim 1 wherein at least a portion of the door includes an inner door skin offset from an outer door skin in a double-wall configuration, wherein the door further includes a foam core positioned between the inner and outer door skins, and wherein the inner and outer door skins and the foam core are formed from the same material.
7. The galley cart of claim 1 , further comprising a door with a cool air aperture positioned at least proximate to the body, wherein the cool air aperture is configured to let cool air from an exterior source flow into the body.
8. The galley cart of claim 1 , further comprising a door hingeably attached to the body, wherein the door includes a cool air aperture configured to let cool air from an exterior source flow into the body.
9. The galley cart of claim 1 wherein the horizontal shelf includes a foam core positioned between a first shelf skin and a second shelf skin.
10. The galley cart of claim 1 wherein the horizontal shelf includes a foam core positioned between a first shelf skin and a second shelf skin, and wherein the foam core and the first and second shelf skins are formed from the same material.
11. A galley cart for use on an aircraft, the galley cart comprising:
a body configured to be moved along a passenger aisle of the aircraft, the body including a one-piece plastic shell having an inner skin offset from an outer skin in a double-wall configuration, the one-piece plastic shell forming:
a first side portion of the body;
a second side portion of the body;
a top portion of the body;
a bottom portion of the body, wherein the first side portion is spaced apart from the second side portion, wherein the top portion extends between the first and second side portions, and wherein the bottom portion is spaced apart from the top portion and extends between the first and second side portions; and
a plurality of horizontal shelves extending from the first side portion to the second side portion between the top and bottom portions;
a plurality of threaded inserts molded into the one-piece plastic shell;
a door;
a plurality of hinges attached to the door;
a first plurality of threaded fasteners engaging a first portion of the threaded inserts and attaching the plurality of hinges to the one-piece plastic shell to pivotally attach the door to the body;
a plurality of rollers; and
a second plurality of threaded fasteners engaging a second portion of the threaded inserts and attaching the plurality of rollers to a lower portion of the one-piece plastic shell for moving the body along a passenger aisle of an aircraft.
12. The galley cart of claim 11 wherein the one-piece plastic shell further includes core material positioned between the inner and outer skins of the one-piece plastic shell.
13. The galley cart of claim 11 wherein the one-piece plastic shell further includes a foam core positioned between the inner and outer skins of the one-piece plastic shell.
14. The galley cart of claim 11 wherein the one-piece plastic shell further includes a foam core positioned between the inner and outer skins of the one-piece plastic shell, and wherein the inner and outer skins and the foam core are formed from the same material.
15. The galley cart of claim 11 wherein the one-piece plastic shell is a first one-piece plastic shell, and wherein the door comprises a second one-piece plastic shell.
16. The galley cart of claim 11 wherein the one-piece plastic shell is a first one-piece plastic shell, wherein the door comprises a second one-piece plastic shell, and wherein the second one-piece plastic shell includes an inner door skin offset from an outer door skin in a double-wall configuration.
17. The galley cart of claim 11 wherein the one-piece plastic shell is a first one-piece plastic shell, wherein the galley cart further comprises a second one-piece plastic shell at least partially forming a door hingeably attached to the body, and wherein the second one-piece plastic shell includes a cool air aperture configured to let cool air from an exterior source flow into the body.
18. The galley cart of claim 17 wherein the cool air aperture is a first aperture, and wherein the second one-piece plastic shell further includes a second aperture configured to let air exit the body.