Patent Description:
Many aircraft are provided with a galley where food and/or beverages may be stored and may be prepared for serving during flight. It is common for an aircraft galley to be designed with an initial frame or "monument" into which galley inserts may be added. Galley inserts include refrigerators, freezers, ovens, microwave ovens, beverage dispensers such as coffer makers, as well as storage cabinets. The galley inserts in a given aircraft may be made by manufacturers different from the aircraft manufacturer, and may be designed to meet certain size and weight limitations such that the galley inserts may be slotted into the frame in the galley. Further, the galley inserts in a given galley may be swapped out and replaced as desired during the service life of the aircraft, e.g. for repair of the inserts or for replacement with another insert. Replacement may be done, for example, with a replacement insert of the same type as the insert being replaced, or with a different type of insert (e.g. swapping a refrigerator insert with an oven insert).

Such conventional galley inserts have generally been considered satisfactory for their intended purpose however there is a need for improved inserts. <CIT> relates to a galley monument with a charging station. <CIT> relates to composite sandwich structures.

According to a first aspect, there is provided a galley insert comprising: a housing; and a door; wherein the housing made from a first material, wherein the first material comprises: a first layer of continuous-fibre reinforced thermoplastic, CFRT, a second layer of CFRT, and a foam core arranged between the first and second layers of CFRT, wherein the second layer forms an outermost surface of the housing.

The door is made from the first material, wherein the second layer forms an outermost surface of the door.

The door may comprise a display, and/or a handle, and/or a vent for allowing airflow through door.

The galley insert may be one of: an oven, a refrigerator, a beverage maker, and a cupboard.

The first material may have a thickness of less than five millimetres.

The fibres of the CFRT may be selected from the group of: glass fibres, metal fibres, aramid fibres, and carbon fibres.

The thermoplastic of the CFRT may be selected from the group of: polyetheimide (PEI), polysulphone (PS), polyethersulphone (PES), polyphenylsulphone (PPSU), polyetheretherketone (PEEK), polyvinylchloride (PVC), polypropelene (PP), polycarbonate (PC), and polyethylene (PE) and combinations thereof.

The foam core may be made from a thermoplastic selected from the group of: polyetheimide (PEI), polysulphone (PS), polyethersulphone (PES), polyphenylsulphone (PPSU), polyetheretherketone (PEEK), polyvinylchloride (PVC), polypropelene (PP), polycarbonate (PC), and polyethylene (PE) and combinations thereof.

The housing may comprise a first sidewall, a second sidewall, opposite the first sidewall, a top wall and a bottom wall, and a rear wall, wherein each of the top surface, bottom surface, and first and second side walls do not include one or more guide strips for positioning the galley insert relative to a frame.

According to a second aspect, there is provided an aircraft comprising: a galley; and at least one galley insert arranged in the galley; wherein the galley insert is a galley insert according to the first aspect.

According to a third aspect, there is provided a method of making a galley insert, the method comprising: forming a housing for the galley insert from a first material, wherein the first material comprises: a first layer of continuous-fibre reinforced thermoplastic, CFRT, a second layer of CFRT, and a foam core arranged between the first and second layers of CFRT, wherein the second layer forms an outermost surface of the housing; and connecting a door to the housing to form the galley insert.

The method may comprise a step of selecting the fibres of the CFRT from the group of: glass fibres, metal fibres, aramid fibres, and carbon fibres.

The method may comprise a step of selecting the thermoplastic of the CFRT from the group of: polyetheimide (PEI), polysulphone (PS), polyethersulphone (PES), polyphenylsulphone (PPSU), polyetheretherketone (PEEK), polyvinylchloride (PVC), polypropelene (PP), polycarbonate (PC), and polyethylene (PE) and combinations thereof.

The method may comprise a step of selecting a foam of the foam core from the group of: polyetheimide (PEI), polysulphone (PS), polyethersulphone (PES), polyphenylsulphone (PPSU), polyetheretherketone (PEEK), polyvinylchloride (PVC), polypropelene (PP), polycarbonate (PC), and polyethylene (PE) and combinations thereof.

The housing and door together may define an interior space of the galley insert, wherein the method may then further comprise a step of installing one or more components in the interior space, wherein the one or more components include any of: a heating element, a light, a refrigeration circuit, and a shelf.

Certain embodiments of the present disclosure will now be described in greater detail by way of example only and with reference to the accompanying drawings in which:.

<FIG> shows a perspective view of an aircraft galley <NUM> having a plurality of galley inserts <NUM> installed therein. Each galley insert <NUM> may be one of: an oven, a refrigerator, a freezer, a beverage maker, or a storage cupboard. A storage cupboard may contain one or more shelves. In this way, a given aircraft may have a galley <NUM> that has a desired number of ovens, refrigerators, freezers, beverage makers, and storage cupboards. In an aircraft where, for example, hot food will not be served during flight, the galley may be fitted with more refrigerators and beverage makers for storing and preparing beverages. Other aircraft may have one or more galley inserts <NUM> that are an oven or microwave oven, for preparing hot food for passengers and/or crew.

<FIG> shows a perspective view of a galley insert <NUM>. The galley insert <NUM> has a door <NUM> allowing access to an interior space <NUM> of the galley insert <NUM>. A handle <NUM> is provided for opening and closing the door <NUM>, and the handle <NUM> may be connected to one or more latches 118a,120a for holding the door <NUM> closed. The door <NUM> is mounted to a housing <NUM> of the galley insert <NUM>. The door <NUM> may be considered to define a front of the galley insert <NUM>, while the housing <NUM> provides the other outermost surfaces of the galley insert <NUM>, including: a top wall, a bottom wall, left and right sidewalls, and the rear wall of the galley insert <NUM>. The housing <NUM> and door <NUM> together define an interior space <NUM> of the galley insert <NUM>.

The door <NUM> has a display <NUM> and an air vent <NUM>. The latches 118a, 120a may be retractable into the body of the door <NUM> when the handle <NUM> is turned. The latches <NUM><NUM>,120a may engage with corresponding recesses in the housing <NUM> to hold the door <NUM> shut.

The housing <NUM> and door <NUM> may thus define the outer extent of the galley insert <NUM>, such that the galley insert <NUM> may be handled as a single distinct unit, and may be installed as a single unit in a frame or monument in the aircraft galley <NUM>. Similarly, the galley insert <NUM> may be removed as a single unit from the galley <NUM>.

The interior space <NUM> may store different components of the galley insert <NUM>, depending on the type of galley insert <NUM>. For example, a refrigerator galley insert <NUM> may have a refrigeration circuit and cooled compartment in the interior space <NUM>, said refrigeration circuit for cooling the compartment and any items therein (e.g. food or beverages). By way of another example, an oven galley insert <NUM> may have heating elements and a heated compartment arranged in the interior space <NUM>, said heating elements for heating the compartment and any items therein. In both of the aforementioned cases, the door <NUM> may allow a user to access the heated/cooled interior space <NUM>.

The housing <NUM> may have one or more ports (not shown) to allow a power cable and/or a fluid pipe to connect components within the interior space <NUM> of the galley insert <NUM> to a power supply or a fluid supply, as appropriate, that is provided in the galley <NUM>. Such ports will typically be in the rear of the galley insert <NUM>, i.e. on a side opposite the door <NUM>.

<FIG> shows a cross-section of a material <NUM> used to form the housing <NUM>. The material <NUM> may be used to form all, or substantially all, of the housing <NUM>. The material <NUM> is also used to form the majority of the door <NUM>, all parts except for e.g. the latches 118a,120a, the handle <NUM>, the display <NUM>, a hinge connecting the door <NUM> to the housing <NUM>, and/or the vent <NUM>.

The material <NUM> comprises two layers <NUM>, <NUM>, and a core <NUM>. The first layer <NUM> is a continuous-fibre reinforced thermoplastic material (hereafter referred to as a "CFRT material"). The second layer <NUM> is a CFRT material. The core <NUM> is a foam material and is disposed between the first layer <NUM> and the second layer <NUM>. In use, the second layer <NUM> forms the outermost surface of the housing <NUM>. The first layer <NUM> forms an interior surface of the housing <NUM>. The interior surface of the housing <NUM>, in conjunction with an interior surface of the door <NUM>, when closed, defines the interior space <NUM> of the galley insert <NUM>.

The core <NUM> is enclosed within the first <NUM> and second <NUM> layers and is not accessible without cutting through or otherwise removing one of the layers <NUM>,<NUM>.

A CFRT material will typically substantially or entirely consists of: continuous fibres of a strong material encased in a thermoplastic resin. The resin holds the otherwise-flexible fibres in place and the fibres, in turn, provide substantial strength to the overall material.

Typically, the fibres may be arranged in a mold in a desired shape or format, such as a woven or non-woven fabric, and then the fibres are impregnated with a liquid thermoplastic resin under pressure. During formation, the liquid resin flows around and between the fibres. The liquid thermoplastic is then cooled, or allowed to cool, until it solidifies. The resulting part made from the CFRT material may then be removed from the mold.

The first layer <NUM> may use the same material for the fibres as used in the second layer <NUM>, or different fibre materials may be used.

The first layer <NUM> may use the same thermoplastic as used in the second layer <NUM>, or different thermoplastics may be used.

The foam material for the core <NUM> may be formed from a thermoplastic that is swelled or otherwise caused to foam.

Suitable thermoplastics for the foam include polyetheimide (PEI), polysulphone (PS), polyethersulphone (PES), polyphenylsulphone (PPSU), polyetheretherketone (PEEK), polyvinylchloride (PVC), polypropelene (PP), polycarbonate (PC), and polyethylene (PE) and combinations thereof. These thermoplastics may be made into a foam using an appropriate swelling agent, or by gas injection.

Suitable fibres for the first layer <NUM> and for the second layer <NUM> include: glass fibres, metal fibres, aramid fibres (e.g. Kevlar™), and carbon fibres.

Suitable thermoplastics for the CFRT include: PEI, PPSU, PS, PEEK, PC, PES, PU, PC, or PP.

The material <NUM> may comprise further components, including one or more of: reinforcing fibres within the foam material of the core <NUM>; reinforcing particles within the foam material of the core <NUM>; a glue layer or a surface treatment to improve bonding between the first layer <NUM> and the core <NUM> and/or between the core <NUM> and the second layer <NUM>; and one or more intermediate layers of CFRT material between the first <NUM> and second <NUM> layers.

The choice of foam material may be driven by thermal insulation properties. The choice of material for the fibres may be driven by strength and stiffness requirements for the layer. The choice of thermoplastic may be driven by the intended operating temperatures of the galley insert <NUM>.

The specific choices made for the first layer <NUM>, second layer <NUM>, and core <NUM>, may depend on the intended type of galley insert <NUM>.

For example, for a galley insert <NUM> that is an oven, it may be important to have a more-heat resistant first layer <NUM> (i.e. on the side of the housing facing the interior space <NUM>) compared to a galley insert <NUM> that is not an oven or microwave oven. Similarly, in this oven example, the foam material for the core <NUM> may be chosen on the basis of its insulation properties as compared to a galley insert <NUM> that is not an oven or microwave oven.

The choice of thermoplastic for the second layer <NUM>, which forms an outermost surface of the housing <NUM>, may for example be selected based on scratch resistance or ease-of-colouration, The specific combination of thermoplastic and fibres used in the (inner) first layer <NUM> may be different from the specific combination of the (outer) second layer <NUM> based on the different requirements for these two layers.

The material <NUM> may have an overall thickness T that is equal to the sum of a thickness T1 of the first layer <NUM>, a thickness T2 of the core <NUM>, and a thickness T3 of the second layer <NUM>. In some embodiments, the overall thickness T is less than five millimeters (<NUM>).

Galley inserts <NUM> are typically designed to fit into a slot in the frame in the galley <NUM> and therefore these galley inserts <NUM> must have predefined outer measurements. That is, for example, a galley insert <NUM> may be designed to have a predefined length from the front of the door <NUM> to the outermost extent of the rear wall of the housing <NUM>. Similarly, the galley insert <NUM> may have a predefined width between the outer side of the left side way and the outer side of the right sidewall.

As such, having a thinner material <NUM> for the housing <NUM> may allow for a larger interior space <NUM> for a given exterior size of galley insert <NUM>. Of course, a thinner section material will typically be weaker and/or provide less thermal insulation compared to a thicker section of the same material. Thus, there is a balance to be struck between providing a larger interior space <NUM> within the housing <NUM> against the need for sufficient strength, stiffness, and thermal insulation provided by the housing <NUM>.

The use of CFRT layers <NUM>,<NUM> may provide a number of advantages over traditional housings for galley inserts. Firstly, CFRT layers may be made very strong, and can be capable of producing housings <NUM> (and doors <NUM>) which are stronger and lighter than those of traditional galley inserts, such as those made of metals such as aluminium. Additionally, CFRT layers may be pre-coloured. This may allow for increased durability and life span of the galley inserts, as a pre-coloured CFRT layer will be more resistant to scratches and sink marks, compared to e.g. a painted galley insert. There is no single, thin, layer of paint or dye that defines the colour of the galley insert <NUM>, as has previously been the case in traditional galley inserts. Galley inserts <NUM> formed with the material <NUM> having pre-coloured CFRT layers (<NUM> and/or <NUM>) may exhibit heightened scratch resistance. Further, the cost to produce and maintain such galley inserts <NUM> may be reduced as the need for paint and paint repairs may be decreased.

In addition to being stronger and lighter than traditional oven galley inserts, galley inserts <NUM> produced using the material <NUM> for the housing <NUM> (and for the door <NUM> as well) may provide thermal insulation advantages over traditional oven doors. Due to the bonded, sandwiched construction of the material shown in <FIG>, insulation may be increased throughout the oven. In effect, this may lead to lower temperatures at the external surface of the oven galley insert <NUM>. Not only do lower external surface temperatures lead to safer ovens, but it also leads to heat conservation and energy savings. Improved insulation at a rear of the galley insert and at the top, bottom, and left and right sides may also reduce undesirable heat transfer to adjacent galley units <NUM>. Thus, for example, an oven galley insert may be arranged adjacent to a refrigerator galley insert or a cupboard galley insert, and the improved insulation offered by the material may reduce undesirable heat transfer from the oven galley insert to goods stored in the refrigerator galley insert/cupboard galley insert.

Saving weight is also a significant factor in the aircraft industry. Any weight savings in the production of aircraft components or equipment may lead to improved aircraft fuel efficiency. The material <NUM> described hereinabove for the housing <NUM> may be lighter than comparably-strong metal housing, which may allow the overall galley insert <NUM> to be significantly lighter than known designs of galley insert having a metal housing.

As the material <NUM> may have greater scratch resistance compared to known designs where a metal housing is painted, the housing <NUM> may have no slide strips. Slide strips are used on metal-housing galley inserts to guide the galley insert into its space in the frame or monument so as to avoid scratching the painted surface of the galley insert. These guide strips help avoid scratching paint on the metal housing of the galley insert as it is inserted or removed. These guide strips add weight and take up space within the galley. Eliminating the need for guide strips may therefore save weight and allow more efficient use of the available space. Thus, as the housing <NUM> of the present disclosure does not require slide strips due to its scratch resistance, further weight savings may be realised.

The housing <NUM>, as shown in <FIG>, has a three-dimensional shape. This may be made by joining together a plurality of panels of the material <NUM>. Panels of the material <NUM> may be joined to one another by a variety of methods including: welding, gluing, or pressing. Welding may include ultrasonic welding or infrared welding for example.

Alternatively, a single panel of the material <NUM> may be pressed into the desired shape for the housing <NUM>. Such pressing may occur alongside heating (either local heating at bend-points or general heating of the material <NUM>) near a glass transition temperature the thermoplastic, or one of the thermoplastics, used in the material <NUM>.

Either after or before forming the housing <NUM>, one or more holes may be made in the material <NUM>, so as to allow access through the housing <NUM> to the interior space <NUM>. Such holes may allow a power cable and/or a fluid pipe to connect from the galley <NUM> to components (e.g. heating elements, refrigeration components, a light source etc.) inside the housing <NUM>. The fluid pipe may be to attach to a water supply or to a gas supply, such as an air supply.

Claim 1:
A galley insert (<NUM>) comprising:
a housing (<NUM>); and
a door (<NUM>);
wherein the housing is made from a first material (<NUM>), characterized in that the first material comprises:
a first layer (<NUM>) of continuous-fibre reinforced thermoplastic, CFRT, a second layer (<NUM>) of CFRT, and a foam core (<NUM>) arranged between the first and second layers of CFRT, wherein the second layer forms an outermost surface of the housing (<NUM>); and
the door (<NUM>) is made from the first material, and wherein the second layer forms an outermost surface of the door.