Reaction-Injection-Molded Cart and Method of Manufacture

Abstract

One advantageous embodiment of the present invention is a reaction-injection-molded galley cart ( 10 ) for an aircraft. This cart ( 10 ) includes a body, which is configured to move along a passenger aisle of the aircraft. The body is comprised of a one-piece plastic shell ( 12 ) having a first side portion ( 28 ), a second side portion ( 30 ) spaced apart from the first side portion ( 28 ), a top side portion ( 24 ) extending between the first side portion ( 28 ) and the second side portion ( 30 ), and a bottom side portion ( 32 ) extending between the first side portion ( 28 ) and the second side portion ( 30 ). This one-piece plastic shell ( 12 ) includes at least one layer ( 36 ) of a reaction-injection-molded material.

1 . A reaction-injection-molded galley cart for an aircraft, comprising: 
 a body configured to move along a passenger aisle of the aircraft, said body having a one-piece plastic shell that forms a first side portion, a second side portion, a top side portion, and a bottom side portion of said body;    wherein said first side portion is spaced apart from said second side portion;    wherein said top side portion extends between said first side portion and said second side portion;    wherein said bottom side portion extends between said first side portion and said second side portion;    wherein said one-piece plastic shell includes at least one layer of a reaction-injection-molded material.    
   
   
       2 . The reaction-injection-molded galley cart recited in  claim 1  wherein said at least one layer of reaction-injection-molded material has a plurality of fasteners embedded therein.  
   
   
       3 . The reaction-injection-molded galley cart recited in  claim 1  wherein said plurality of fasteners is selected from the group consisting of a plurality of castors, a plurality of hinges, and a plurality of detent flanges.  
   
   
       4 . The reaction-injection-molded galley cart recited in  claim 1  wherein said plurality of fasteners mounts at least one decorative panel to said body.  
   
   
       5 . The reaction-injection-molded galley cart recited in  claim 1  wherein said at least one layer of reaction-injection-molded material includes a base layer and a foam layer coupled to said base layer.  
   
   
       6 . The reaction-injection-molded galley cart recited in  claim 1  wherein said top side portion of said one-piece plastic shell has a tray member coupled thereto.  
   
   
       7 . The reaction-injection-molded galley cart recited in  claim 1  wherein said one-piece plastic shell defines an interior cavity and a pair of opposing open ends in communication with said interior cavity, said pair of opposing open ends having a pair of panels coupled thereto.  
   
   
       8 . The reaction-injection-molded galley cart recited in  claim 7  wherein at least one said pair of panels is a door for selectively providing access to said interior cavity.  
   
   
       9 . The reaction-injection-molded galley cart recited in  claim 1  wherein said one-piece shell construction has a plurality of grooves formed therein for receiving and supporting at least one tray within said interior cavity.  
   
   
       10 . The reaction-injection-molded galley cart recited in  claim 9  wherein said plurality of grooves are formed in said first side portion and said second side portion.  
   
   
       11 . A reaction-injection-molded galley cart for an aircraft, comprising: 
 a body configured to move along a passenger aisle of the aircraft, said body having a one-piece plastic shell that forms a first side portion, a second side portion, a top side portion, and a bottom side portion of said body;    wherein said first side portion is spaced apart from said second side portion;    wherein said top side portion extends between said first side portion and said second side portion;    wherein said bottom side portion extends between said first side portion and said second side portion;    wherein said one-piece plastic shell includes at least one layer of a reaction-injection-molded material with a plurality of reinforcement members embedded therein.    
   
   
       12 . The reaction-injection-molded galley cart recited in  claim 11  wherein said plurality of reinforcement members includes at least one of a plurality of carbon fibers and a plurality of glass fibers.  
   
   
       13 . The reaction-injection-molded galley cart recited in  claim 11  wherein said at least one layer of reaction-injection-molded material has a plurality of fasteners embedded therein.  
   
   
       14 . The reaction-injection-molded galley cart recited in  claim 11  wherein said plurality of fasteners is selected from the group consisting of a plurality of castors, a plurality of hinges, and a plurality of detent flanges.  
   
   
       15 . The reaction-injection-molded galley cart recited in  claim 11  wherein said plurality of fasteners mounts at least one decorative panel to said body.  
   
   
       16 . The reaction-injection-molded galley cart recited in  claim 11  wherein said at least one layer of reaction-injection-molded material includes a base layer and a foam layer coupled to said base layer.  
   
   
       17 . The reaction-injection-molded galley cart recited in  claim 11  wherein said top side portion of said one-piece plastic shell has a tray member coupled thereto.  
   
   
       18 . The reaction-injection-molded galley cart recited in  claim 11  wherein said one-piece plastic shell defines an interior cavity and a pair of opposing open ends in communication with said interior cavity, said pair of opposing open ends having a pair of panels coupled thereto.  
   
   
       19 . The reaction-injection-molded galley cart recited in  claim 18  wherein at least one said pair of panels is a door for selectively providing access to said interior cavity.  
   
   
       20 . The reaction-injection-molded galley cart recited in  claim 11  wherein said one-piece shell construction has a plurality of grooves formed therein for receiving and supporting a tray within said interior cavity.  
   
   
       21 . The reaction-injection-molded galley cart recited in  claim 20  wherein said plurality of grooves are formed in said first side portion and said second side portion.  
   
   
       22 . The reaction-injection-molded galley cart recited in  claim 11  wherein said base layer is generally impermeable to fluids.  
   
   
       23 . A system for manufacturing a reaction-injection-molded galley cart for an aircraft, comprising: 
 a first mold;    a resin applicator device for applying at least one layer of reaction-injection-molded material to said first mold;    a second mold for clamping to said first mold and forming a one-piece plastic shell;    at least one motor coupled to at least one of said first mold, said resin applicator device, and said second mold;    a controller coupled to said at least one motor for controlling movement of at least one of said first mold, said resin applicator device, and said second mold;    wherein said one-piece plastic shell has a first side portion, a second side portion spaced apart from said first side portion, a top side portion extending between said first side portion and said second side portion, and a bottom side portion extending between said first side portion and said second side portion.    
   
   
       24 . A reaction-injection-molded galley cart for an aircraft manufactured by the process comprising: 
 rotating a first mold;    applying a base layer to said first mold;    applying a foam layer to said base layer;    embedding at least one reinforcement member in at least one of said base layer and said foam layer;    halting a spin of said first mold;    clamping a second mold to said first mold;    applying pressure to said base layer and said foam layer; and    heating said base layer and said foam layer; and    wherein said base layer and said foam layer form a one-piece plastic shell with a first side portion, a second side portion spaced apart from said first side portion, a top side portion extending between said first side portion and said second side portion, and a bottom side portion extending between said first side portion and said second side portion;    wherein at least said foam layer comprises reaction-injection-molded material.    
   
   
       25 . A method for manufacturing a reaction-injection-molded galley cart for an aircraft, comprising: 
 rotating a first mold;    applying a base layer to said first mold;    applying a foam layer to said base layer;    halting a spin of said first mold;    clamping a second mold to said first mold;    applying pressure to said base layer and said foam layer; and    heating said base layer and said foam layer;    wherein said base layer and said foam layer form a one-piece plastic shell with a first side portion, a second side portion spaced apart from said first side portion, a top side portion extending between said first side portion and said second side portion, and a bottom side portion extending between said first side portion and said second side portion;    wherein said foam layer comprises reaction-injection-molded material.    
   
   
       26 . The method recited in  claim 25  further comprising: 
 applying an outer layer to said foam layer.    
   
   
       27 . The method recited in  claim 25  further comprising: 
 securing at least one fastener to at least on of said first mold and said second mold; and    embedding said at least one fastener in at least one of said base layer and said foam layer.    
   
   
       28 . The method recited in  claim 25  further comprising: 
 coupling a tray member to said top side portion of said one-piece plastic shell.    
   
   
       29 . The method recited in  claim 25  further comprising: 
 coupling a pair of panels to a pair of opposing ends of said one-piece plastic shell.    
   
   
       30 . The method recited in  claim 29  wherein at least one of said pair of panels is a door for selectively providing access to an interior cavity that is defined by said one-piece plastic shell.  
   
   
       31 . The method recited in  claim 25  further comprising: 
 coupling a plurality of wheels to said bottom side portion of said one-piece plastic shell.    
   
   
       32 . A method for manufacturing a reaction-injection-molded galley cart for an aircraft, comprising: 
 rotating a first mold;    applying a base layer to said first mold;    applying a foam layer to said base layer;    embedding a plurality of reinforcement members within at least one of said base layer and said foam layer;    halting a spin of said first mold;    clamping a second mold to said first mold;    applying pressure to said base layer and said foam layer; and    heating said base layer and said foam layer; and    actuating a computer-controlled mechanism for moving at least one of said first mold, said second mold, and a resin applicator device;    wherein said base layer and said foam layer form a one-piece plastic shell with a first side portion, a second side portion spaced apart from said first side portion, a top side portion extending between said first side portion and said second side portion, and a bottom side portion extending between said first side portion and said second side portion;    wherein said foam layer comprises reaction-injection-molded material.    
   
   
       33 . The method recited in  claim 32  further comprising: 
 applying an outer layer to said foam layer.    
   
   
       34 . The method recited in  claim 32  further comprising: 
 securing at least one fastener to said first mold; and    embedding said at least one fastener in at least one of said base layer and said foam layer.    
   
   
       35 . The method recited in  claim 32  further comprising: 
 coupling a tray member to said top side portion of said one-piece plastic shell.    
   
   
       36 . The method recited in  claim 32  further comprising: 
 coupling a pair of panels to a pair of opposing ends of said one-piece plastic shell.    
   
   
       37 . The method recited in  claim 36  wherein at least one of said pair of panels is a door for selectively providing access to an interior cavity that is defined by said one-piece plastic shell.  
   
   
       38 . The method recited in  claim 32  further comprising: 
 coupling a plurality of wheels to said bottom side portion of said one-piece plastic shell.