Aircraft Galley Carts and Associated Methods of Manufacture

Abstract

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, the 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, 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.    
   
   
       2 - 8 . (canceled)  
   
   
       9 . 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.  
   
   
       10 . 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.  
   
   
       11 - 14 . (canceled)  
   
   
       15 . 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 at least one of a first side portion, a second side portion, a top portion, and 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.    
   
   
       16 - 20 . (canceled)  
   
   
       21 . The galley cart of  claim 15  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.  
   
   
       22 . The galley cart of  claim 21  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.  
   
   
       23 - 28 . (canceled)  
   
   
       29 . A method for manufacturing a galley cart for use on an aircraft, the method comprising: 
 loading plastic resin into a mold;    flowing the plastic resin over an interior surface of the mold to form a one-piece plastic shell, the one-piece plastic shell having an interior portion configured to support a plurality of airline meals;    removing the one-piece plastic shell from the mold; and    attaching a door to the one-piece plastic shell, wherein the door is movable to provide access to the interior portion of the one-piece plastic shell.    
   
   
       30 . The method of  claim 29  wherein loading plastic resin into a mold includes injecting molten plastic resin into the mold.  
   
   
       31 . The method of  claim 29 , further comprising: 
 heating the resin; and    rotating the mold to flow the heated resin over the interior surface of the mold.    
   
   
       32 . The method of  claim 29  wherein flowing the plastic resin over an interior surface of the mold includes forming a one-piece plastic shell having an inner skin offset from an outer skin in a double-wall configuration.  
   
   
       33 . The method of  claim 29  wherein flowing the plastic resin over an interior surface of the mold includes forming a one-piece plastic shell having an inner skin offset from an outer skin in a double-wall configuration, and further forming a core material positioned between the inner and outer skins.  
   
   
       34 . The method of  claim 29  wherein flowing the plastic resin over an interior surface of the mold includes forming a one-piece plastic shell having an inner skin offset from an outer skin in a double-wall configuration, and further forming a foam plastic core positioned between the inner and outer skins.  
   
   
       35 . The method of  claim 29  wherein flowing the plastic resin over an interior surface of the mold to form a one-piece plastic shell includes forming a plurality of horizontal supports in the interior portion of the one-piece plastic shell, wherein the plurality of horizontal supports are configured to hold the plurality of airline meals.  
   
   
       36 . The method of  claim 29  wherein the plastic resin includes a first portion of plastic resin, wherein the mold includes a first mold, wherein the one-piece plastic shell includes a first one-piece plastic shell, and wherein the method further comprises forming the door by: 
 loading a second portion of plastic resin into a second mold; and    flowing the second portion of plastic resin over an interior surface of the second mold to form a second one-piece plastic shell.    
   
   
       37 . The method of  claim 29  wherein the plastic resin includes a first portion of plastic resin, wherein the mold includes a first mold, wherein the one-piece plastic shell includes a first one-piece plastic shell, and wherein the method further comprises forming the door by: 
 loading a second portion of plastic resin into a second mold; and    flowing the second portion of plastic resin over an interior surface of the second mold to form a second one-piece plastic shell having an inner door skin offset from an outer door skin in a double-wall configuration.    
   
   
       38 . The method of  claim 29  wherein the plastic resin includes a first portion of plastic resin, wherein the mold includes a first mold, wherein the one-piece plastic shell includes a first one-piece plastic shell, and wherein the method further comprises forming the door by: 
 loading a second portion of plastic resin into a second mold; and    flowing the second portion of plastic resin over an interior surface of the second mold to form a second one-piece plastic shell having an aperture, wherein the aperture is configured to let cool air from an exterior source flow into the interior portion of the first one-piece plastic shell.    
   
   
       39 . The method of  claim 29 , further comprising loading at least one insert into the mold, wherein flowing the plastic resin over an interior surface of the mold includes fixing the insert in a portion of the one-piece plastic shell, and wherein attaching a door to the one-piece plastic shell includes engaging the insert.  
   
   
       40 - 42 . (canceled)