CFRT Galley Inserts with Foam Core for Aircraft

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Solution Overview

Problem

Conventional galley inserts in aircraft lack improved materials for strength, durability, and thermal insulation, leading to weight and maintenance issues, as well as inefficiencies in space utilization and heat transfer.

Innovation Solution

The use of a housing and door made from continuous-fibre reinforced thermoplastic (CFRT) with a foam core, where the outer layer forms the surface, providing a strong, lightweight, and thermally insulated structure without the need for guide strips, and allowing for various components such as heating elements and refrigeration circuits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional materials are used for galley insert housing, then manufacturing is simpler, but weight is higher and strength is lower

Engineering Contradiction:

Improvehousing strengthVSAvoidgalley insert weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The housing is constructed from a composite material comprising a foam core material surrounded by a thermoplastic matrix with continuous fibres embedded therein. This composite structure provides high strength-to-weight ratio, achieving both improved strength and reduced weight compared to conventional materials.

Inventive Principle:

Principle #40Composite materials

2Reliability

If conventional materials are used for galley insert housing, then manufacturing is simpler, but durability and thermal insulation are poorer

Engineering Contradiction:

Improvehousing durabilityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The composite material combines foam core for thermal insulation, thermoplastic matrix for durability and scratch resistance, and continuous fibres for structural strength. This multi-functional composite achieves superior reliability while the integrated structure simplifies manufacturing by eliminating separate insulation and structural components.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The continuous fibres are specifically oriented in the thermoplastic matrix to provide enhanced strength and scratch resistance at critical surfaces, while the foam core provides thermal insulation where needed. This local optimization of material properties achieves superior durability without excessive manufacturing complexity.

Inventive Principle:

Principle #3Local quality

3Temperature

If thicker housing material is used, then strength and thermal insulation are improved, but weight increases and space utilization decreases

Engineering Contradiction:

Improvethermal insulation performanceVSAvoidgalley insert volume

Core Design Contradiction:

TemperatureVSVolume of moving object

Solution Approach 1:

The composite structure with foam core and fibre-reinforced thermoplastic shell provides superior thermal insulation performance with minimal thickness. The foam core offers high insulation value per unit thickness, while the fibre-reinforced shell adds structural strength, achieving excellent thermal performance without increasing volume.

Inventive Principle:

Principle #40Composite materials

4Manufacturing precision

If guide strips are added to housing, then positioning accuracy is improved, but manufacturing complexity and weight increase

Engineering Contradiction:

Improvepositioning precisionVSAvoidhousing structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The composite housing structure serves multiple functions: the foam core provides insulation, the thermoplastic matrix provides durability and scratch resistance, and the continuous fibres provide structural strength. This multi-functional integrated structure eliminates the need for separate guide strips, achieving positioning through the housing's inherent structural properties without adding complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution results in galley inserts that are stronger, lighter, and more durable, with enhanced thermal insulation and scratch resistance, reducing weight and maintenance costs while improving energy efficiency and heat management within the aircraft galley.

Implementation Method 1

a foam core arranged between the first and second layers of CFRT

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Implementation Method 2

a first layer of continuous-fibre reinforced thermoplastic, CFRT, a second layer of CFRT

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Data Source

PatentEP4112464B1Galley inserts

Publication Date: 2025.01.01 BE AEROSPACE INC

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AI summary

A galley insert (101) is provided. The galley insert comprising: a housing and a door. The housing is made from a first material that 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. The second layer forms an outermost surface of the housing. A method of making a galley insert (101) is also provided.