LATTICE SUPPORT STRUCTURES

Abstract

The present disclosure is drawn to a lattice support structure, comprising a plurality of fiber-based cross supports intersecting one another to form a multi-layered node. The multi-layered node can be consolidated within a rigid mold in the presence of resin, heat, and pressure. In another embodiment, a lattice support structure can comprise a first cross support comprising fiber material; a second cross support comprising a fiber material, said second cross support intersecting the first cross support; and multi-layered nodes located where the first cross support intersects the second cross support. The multi-layered nodes can comprise at least two layers of the first cross support separated by a least one layer of the second cross support. Also, one of the first cross support or the second cross support can be curved from node to node.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation application claiming the benefit of U.S. patent application Ser. No. 12/542,442, filed Aug. 17, 2009, entitled, “LATTICE SUPPORT STRUCTURES,” which claims the benefit of U.S. Provisional Patent Application No. 61/089,124,” filed on Aug. 15, 2008, entitled, “THREE-DIMENSIONAL GEO-STRUT STRUCTURE AND METHOD OF MANUFACTURE, each of which are incorporated in their entirety by reference and made a part hereof.

BACKGROUND

Structural supports, including lattice-type structural supports, have been developed for many applications which provide high strength performances, but benefit from the presence of less material. In other words, efficient structural supports can possess high strength, and at the same time, be low in weight resulting in high strength/weight ratios. Truss systems have been pursued for many years and continue to be studied and redesigned by engineers with incremental improvements.

In the field of carbon fiber lattice support structures, a primary issue concerning such systems relates to the construction of joints, coupling members of the system together forming a single larger unit. Approaches to coupling the lattice members such as weaving, twisting, mechanical fastening, bypassing of nodes, or the like, have provided marginal results regarding strength performances of the resulting structures. Thus, it would be desirable to provide a lattice support structure that has exceptional node strength and a high level of structural integrity using fiber-based materials.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:

FIGS. 1A-1C depict exemplary embodiments of lattice support structures in accordance with embodiments of the present disclosure;

FIGS. 2A-2C depict alternative exemplary embodiments of lattice support structures in accordance with embodiments of the present disclosure;

FIGS. 3A-3C depict alternative exemplary embodiments of lattice support structures in accordance with embodiments of the present disclosure;

FIGS. 4A-4C depict alternative exemplary embodiments of lattice support structures in accordance with embodiments of the present disclosure;

FIG. 5 depicts an alternative exemplary embodiment of another lattice support structure in accordance with embodiments of the present disclosure;

FIGS. 6A-6F depict various arrangements of cross supports and various node configurations in accordance with embodiments of the present disclosure;

FIG. 7 depicts a multi-layered node configuration prior to fusion and/or consolidation in accordance with embodiments of the present disclosure, where each cross support includes multiple layers and the layers are stacked with other cross support material from different cross supports therebetween;

FIG. 8 depicts node layering in cross section in accordance with one embodiment of the present disclosure;

FIG. 9 depicts node layering in cross section in accordance with another embodiment of the present disclosure;

FIG. 10, depicts a cutaway portion of an exemplary consolidated node in accordance with embodiments of the present disclosure; and

FIG. 11 depicts an exemplary consolidated node sectioned orthogonally to the longitudinal axis depicting the change in member width approaching the node and massing of layered material near and on the node.

Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.

DETAILED DESCRIPTION

The following detailed description of representative embodiments of the present disclosure makes reference to the accompanying drawings, which form a part hereof and in which are shown, by way of illustration, various representative embodiments in which the teachings of the disclosure can be practiced. While these embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, it should be understood that other embodiments can be realized and that various changes can be made to the disclosure without departing from the spirit and scope of the present invention. As such, the following detailed description is not intended to limit the scope of the disclosure as it is claimed, but rather is presented for purposes of illustration, to describe the features and characteristics of the present disclosure, and to sufficiently enable one skilled in the art to practice the disclosure. Accordingly, the scope of the present invention is to be defined by the appended claims.

In accordance with this, a lattice support structure can comprise a plurality of fiber-based cross supports intersecting one another to form a multi-layered node. The multi-layered node can be consolidated within a groove of a rigid mold in the presence of resin, heat, and pressure. In one embodiment, the cross supports can have a thickness where the multi-layered node is thinner than the sum of the thickness of each cross support at the multi-layered node.

In another embodiment, a lattice support structure can comprise a first cross support comprising fiber material, and a second cross support comprising a fiber material, where the second cross support intersects the first cross support. The lattice support structure can also include multi-layered nodes located where the first cross support intersects the second cross support. The multi-layered nodes can comprise at least two layers of the first cross support separated by a least one layer of the second cross support. Additionally, at least one of the first cross support or the second cross support can be curved from node to node.

It is noted that when referring to a “multi-layered” node, what is meant is that the cross supports are not merely stacked on top of one another, but rather, a first individual cross support has multiple layers with one or more layer(s) of material from other cross supports therebetween. Thus, in order to be “multi-layered, there must be at least one cross support or layer of at least one cross support that is between at least two layers of another cross support. Typically, however, each cross support of the node is layered with other cross support layers therebetween (as shown hereinafter in FIG. 7).

It is also notable that the present disclosure provides lattice support structures or fiber-based composite articles. Examples of specific methods for the fabrication thereof and related systems, as well as solid mandrels used to form such structures, can be found in Applicants' copending U.S. patent applications filed Aug. 17, 2009 under Attorney Docket Nos. 3095-003.NP, 3095-004.NP, and 3095-006.NP, each of which is incorporated herein by reference in its entirety.

In further detail with respect to embodiments of the present disclosure, several figures provided herein setting forth additional features of the lattice support structures of the present disclosure are provided.

With specific reference to FIGS. 1A, 1B, and 1C, one embodiment of a lattice support structure is shown. FIG. 1A and FIG. 1C are identical, showing different views of the same structure. FIG. 1B is identical to FIG. 1A, except that it does not include optional support collars 20 on each end of the lattice support structure. These lattice support structures each comprise a plurality of fiber-based cross supports intersecting one another to form several multi-layered nodes 22. It is noted that there are eight longitudinal cross supports 24 and eight helical cross supports 26a, 26b (four twisting clockwise 26a from top to bottom and four twisting counterclockwise 26b from top to bottom). Nodes are formed in this embodiment where three cross supports (one longitudinal cross support, one clockwise helical cross support, and one counterclockwise helical cross support) intersect. The helical cross supports form curved node-to-node cross support segments. This structure also demonstrates 4 helical cross supports taken at a 1 turn per 7 inches pitch, with 4 counter wrapped helical cross supports of equal pitch combined with longitudinal cross supports, coupled at a plurality of multi-layered nodes where the ends have been consolidated by a collar. It is noted that this structure profile, including number and direction of turns, number and position of various cross supports, etc., is merely exemplary, and can be modified slightly or significantly in accordance with embodiments of the present disclosure.

With specific reference to FIGS. 2A, 2B, and 2C, another embodiment of a lattice support structure is shown. FIG. 2A and FIG. 2C are identical, showing different views of the same structure. FIG. 2B is identical to FIG. 2A, except that it does not include optional support collars 20 on each end of the lattice support structure. These lattice support structures each comprise a plurality of fiber-based cross supports intersecting one another to form several multi-layered nodes 22. It is noted that there are eight longitudinal cross supports 24 and eight helical cross supports 26a, 26b (four twisting clockwise 26a from top to bottom and four twisting counterclockwise 26b from top to bottom). Nodes are formed in this embodiment where three cross supports (one longitudinal cross support, one clockwise helical cross support, and one counterclockwise helical cross support) intersect. The helical cross supports form curved node-to-node cross support segments. It is noted that the primary difference between the structures shown in FIGS. 1A-1C and the structures shown in FIGS. 2A-2C is the increased frequency of twists for the helical lattice support structures in FIGS. 2A-2C. This structure also demonstrates 4 helical cross supports taken at a 5 turns per 7 inches pitch, with 4 counter wrapped helical cross supports of equal pitch combined with longitudinal cross supports, coupled at a plurality of multi-layered nodes where the ends have been consolidated by a collar.

With specific reference to FIGS. 3A, 3B, and 3C, another embodiment of a lattice support structure is shown. FIG. 3A and FIG. 3C are identical, showing different views of the same structure. FIG. 3B is identical to FIG. 3A, except that it does not include optional support collars 20 on each end of the lattice support structure. These lattice support structures each comprise a plurality of fiber-based cross supports intersecting one another to form several multi-layered nodes 22a, 22b. Again, it is noted that there are eight longitudinal cross supports 24. However, in this embodiment, there are sixteen (16) helical cross supports 26a, 26b (eight twisting clockwise 26a from top to bottom and eight twisting counterclockwise 26b from top to bottom). Also, in this embodiment, two different types of multi-layered nodes are formed. First, multi-layered nodes 22a are formed where three cross supports (one longitudinal cross support, one clockwise helical cross support, and one counterclockwise helical cross support) intersect. Multi-layered nodes 22b are also formed where two helical cross supports (one clockwise helical and one counterclockwise helical) intersect without a longitudinal cross support. This structure also demonstrates 8 helical cross supports taken at a 2 turns per 7 inches pitch, with 8 counter wrapped helical cross supports of equal pitch combined with longitudinal cross supports, coupled at a plurality of multi-layered nodes where the ends have been consolidated by a collar. It is also noted that additional multi-layered nodes are present that do not include longitudinal cross supports.

With specific reference to FIGS. 4A, 4B, and 4C, another embodiment of a lattice support structure is shown. FIG. 4A and FIG. 4C are identical, showing different views of the same structure. FIG. 4B is identical to FIG. 4A, except that it does not include optional support collars 20 on each end of the lattice support structure. These lattice support structures each comprise a plurality of fiber-based cross supports intersecting one another to form several multi-layered nodes 22. In this embodiment, there are no longitudinal cross supports. Also in this embodiment, there are twelve (12) helical cross supports 26a, 26b (four twisting clockwise 26a from top to bottom and eight twisting counterclockwise 26b from top to bottom). This embodiment thus also demonstrates the ability to design for unidirectional torsion and other loads through varying the number of members in the clockwise direction from those in the counterclockwise direction. Nodes 22 are formed where two helical cross supports (one clockwise helical cross support and one counterclockwise helical cross support) intersect without a longitudinal cross support.

With specific reference to FIG. 5, another embodiment of a lattice support structure is shown. In this FIG., not only are longitudinal cross supports 24 and helical cross supports 26 shown, but circumferential cross supports 28 are also shown. Again, these lattice support structures each comprise a plurality of fiber-based cross supports intersecting one another to form several multi-layered nodes 22a, 22b, 22c. In this embodiment, there are eight helical cross supports and eight longitudinal cross supports, as described previously in FIGS. 1A-1C. However, there are also two additional circumferential cross supports. Thus, in this embodiment, there are three different multi-layered node configurations. First, multi-layered nodes 22a are formed where four cross supports (one longitudinal cross support, one circumferential cross support, one clockwise helical cross support from top to bottom, and one counterclockwise helical cross support from top to bottom) intersect. Multi-layered nodes 22b are also formed where three cross supports (one longitudinal cross support, one clockwise helical cross support from top to bottom, and one counterclockwise helical cross support from top to bottom) intersect. Next, multi-layered nodes 22c are formed where two cross supports (one longitudinal cross support and one circumferential cross support) intersect.

It is noted that FIGS. 1A to FIG. 5 are provided for exemplary purposes only, as many other structures can also be formed in accordance with embodiments of the present disclosure. For example, twist pitch can be modified for helical cross supports, longitudinal cross supports added symmetrically or asymmetrically, circumferential cross supports can be added uniformly or asymmetrically, node locations and/or number of cross supports can be varied, as can the overall geometry of the resulting part including diameter, length and the body-axis path to include constant, linear and non-linear resulting shapes as well as the radial path to create circular, triangular, square and other polyhedral cross-sectional shapes with or without standard rounding and filleting of the corners, etc. In other words, these lattice supports structures are very modifiable, and can be tailored to a specific need. For example, if the weight of a lattice support structure needs to be reduced, then cross lattice support structures can be removed at locations that will not experience as great of a load. Likewise, cross lattice support structures can be added where load is expected to be greater.

In accordance with this, FIGS. 6A-6F provide exemplary relative arrangements for helical, longitudinal, and circumferential cross supports that can be used in forming lattice support structures. Various node placements are also shown in these FIGS. FIG. 6A depicts a longitudinal cross support 24 and helical cross supports 26, forming a multi-layered node 22 at the intersection of all three cross supports. This is similar to that shown in FIGS. 1A-3C and 5. FIG. 6B depicts a longitudinal cross support 24, helical cross supports 26, and a circumferential cross support 28 forming a multi-layered node 22 at the intersection of all four cross supports. FIG. 6C depicts a longitudinal cross support 24, helical cross supports 26, and a circumferential cross support 28 forming three different types of multi-layered nodes 22a, 22b, 22c. FIG. 6D depicts a longitudinal cross support 24 and helical cross supports 26 forming two different types of multi-layered nodes 22a, 22b. FIG. 6E depicts a longitudinal cross support 24, helical cross supports 26, and a circumferential cross support 28 forming three different types of multi-layered nodes 22a, 22b, 22c. It is noted that this arrangement provides two multi-layered nodes that are similar to FIG. 6C (22a, 22b) and one that is different (22c). Specifically, multi-layered node 22c in FIG. 6C comprises a circumferential cross support and a helical cross support, whereas multi-layered node 22c in FIG. 6E comprises a longitudinal cross support and a helical cross support, thus illustrating the flexibility of design of the lattice support structures of the present disclosure. FIG. 6F depicts a longitudinal cross support 24, helical cross supports 26, and a circumferential cross support 28 forming four different types of multi-layered nodes 22a, 22b, 22c, 22d.

Turning to FIG. 7, more detail is provided with respect to forming multi-layered nodes in accordance with embodiments of the present disclosure. Specifically, for illustrative purposes only, the multi-layered node 22 shown in FIG. 6A is shown in more detail prior to heat and pressure fusion or consolidation. As can be seen in this embodiment, a longitudinal cross support 24 and two helical cross supports 26 are shown. Specifically, each cross support comprises multiple layers, and at the multi-layered node, each layer is separated from a previously applied layer by at least one other cross support layer. In this manner, a multi-layered node is formed that can be cured in accordance with embodiment of the present disclosure.

With specific reference to curing, in one embodiment, the curing process comprises applying 90-150 psi nitrogen gas at 250-350° F. for a soak period of about 10 to 240 minutes depending on the size of the part and its coinciding tooling. In this embodiment, the cross supports with layered and interleaved nodes can be applied to a solid mandrel and wrapped with a membrane or bag. Once in place, the pressure from the ambient curing gas provides an even press through the bag on the entire part, thus curing and consolidating the multi-layered nodes.

FIGS. 8 and 9 depict schematic representations of possible multi-layered node structures. Specifically, FIG. 8 depicts layering using tow material of low fiber count and what a nodal cross-section might appear to be like before consolidation and FIG. 9 depicts what the layering would appear like after consolidation. It is noted that the fiber of high fiber-count tow or tape products may appear like FIG. 9 prior to consolidation as well, and after consolidation, the node would appear even more flattened in shape. In these FIGS., it is assumed that six layers of tow or tape are wrapped to demonstrate the leaving of layers in the nodes. In each of these two figures, the cross supports shown on end (along the Z-axis) in cross-section 30 can be assumed to be members which continue into and out of the respective FIG. The cross support material 32 intersecting them (along the X- and Y-axis) represent a single cross-support members, and collectively, these cross supports form nodes of the shape similar to 22b, 22c and 22d in FIGS. 6E and 6F. In these illustrations, the helical cross support is approaching from the left side. Were there to be an additional helical member wrapped in the opposite direction, it would look to be the mirror image of the one shown and approach from the right side of the figures.

FIG. 10 sets forth a cutaway cross-section of a multi-layered node after curing and consolidation of the layered material. Note the cross-sectional area of the member is set into a half-pipe geometry 34 (as consolidated and forced in half-pipe shaped grooves from a solid mandrel), though other geometries are certainly a design option, depending on the shape of the solid mandrel grooves. This consolidated node structure shows a distinction in structure compared to the prior art junctions where weaving and/or braiding are used. Most notably, a build-up of material in the node resulting from coupling the material from various members in various directions allows for the forming of a consolidated node that is compacted and cured, adding strength to the overall structure. Rather than stacking each layer directly on top of the next, the leaving as in FIGS. 8 and 9 allows for individual wraps 36 of tow or tape to end up side-by-side and stacked as a function of the geometry they are forced into before curing. Likewise, FIG. 11 sets forth an exemplary consolidated node sectioned orthogonally to the longitudinal axis depicting the change in member width approaching the node and massing of layered material near and on the node as just described.

In further detail with respect to the embodiments shown in FIGS. 1-11, the present disclosure relates to helical cross supports wrapped around a centerline where the helical cross supports have curved segments rigidly connected end to end and layered with or without axial, radial, or laterally configured lattice support structures (e.g., longitudinal and/or circumferential cross supports) which can be straight or curved end to end. The curves of the helical cross support segments can comply directly with the desired geometric shape of the overall unit. In one embodiment, the structure can include at least two helical cross supports. As described above, at least one of the helical cross supports wraps around the centerline in one direction (clockwise from top to bottom, for example) while at least one other wraps around in the opposite direction (counterclockwise from top to bottom, for example). Though a “top to bottom” orientation is described, this is done for convenience only, as these structures may be oriented other than in a vertical configuration (horizontal, angular, etc.). Helical cross supports wrapped in the same direction can have the same angular orientation and pitch, or can have different angular orientations and pitch. Also, the spacing of the multiple helical cross supports may not necessarily spaced apart at equal distances, though they are often spaced at equal distances. The reverse helical cross supports can be similarly arranged but with an opposing angular direction. These helical cross supports can cross at multi-layered nodes, coupling counter oriented helical cross supports through layering of the filaments. This coupling provides a ready distribution of the load onto the various structural supports. When viewed from centerline, the curving segments of the components can appear to match the desired geometry of the structural unit with no significant protrusions, i.e. a cylindrical unit appears as a circle from the centerline. In this embodiment, all components can share a common centerline.

Additional structural supports can also be included in the lattice support structure. Components which are straight from junction to junction may be included to intersect multi-layered nodes parallel to the centerline to form unidirectional members (e.g. longitudinal cross supports). Components, which can be curved or straight, can also be added circumferentially to intersect with the multi-layered nodes along the length of the lattice support structure. These circumferential cross supports can be added to increase internal strength of the structure. These additional members may be added to intersect at the multi-layered nodes, but do not necessarily need to intersect the nodes formed by the helical cross supports crossing one another, e.g. they may cross at areas between helical-helical nodes. In other words, the longitudinal cross supports and/or the circumferential cross supports may form common multi-layered nodes with helical-helical formed multi-layered nodes, or can form their own multi-layered nodes between the helical-helical formed multi-layered nodes. In either case, the multi-layered nodes can still be formed using filament layering. The count of helical members compared to other members is flexible in certain embodiment to allow for multi-layered nodes to occur only as lattice support structures intersect in a given location, or to allow for multiple node locations composed of two or more, but not all of the members in the structure. The capability of such a design allows versatility in the number of helical cross supports, the coil density, as well as the number of multi-layered nodes or intersections with axial, radial, or lateral components. As a general principle, the more strength desired for an application, the higher the coil density; whereas, the less strength desired, the fewer coils and wider the wrap length per coil may be present.

Structural supports may be covered with a material to create the appearance of a solid structure, protect the member or its contents, or provide for fluid dynamic properties. The current disclosure is therefore not necessarily a traditional pipe, rope, coil, spring, or solid shaft, neither is it a reinforcement for a skin cover. Even though the structures disclosed herein are relatively lightweight, because of its relative strength to weight ratio, these lattice support structures are strong enough to act as stand-alone structural units. Further, these structures can be built without brackets to join individual lattice support structures.

In accordance with one embodiment, the present disclosure can provide a lattice structure where individual supports structures are wrapped with uni-directional tow, where each helical cross support, for example, is a continual strand. Further, it is notable that an entire structure can be wrapped with a single strand, though this is not required. Also, the lattice support structures are not weaved or braided, but rather, can be wrapped layer by layer where a leaving structure is created in the nodes. Thus, where the helical cross supports intersect one another and/or one or more longitudinal and/or circumferential cross supports, these intersections create multi-layered nodes of compounded material which couple the members together. In one embodiment, the composite strand does not change major direction at these multi-layered nodes to form any polyhedral shape when viewed from the axial direction. FIG. 11 as a cross section of a longitudinal member depicts the bending of the helical members intended in this disclosure. This is also evident in FIGS. 1-5 through the creation of cylindrical parts using this technology. Thus, the strand maintains their path in its own axial, circumferential, or helical direction based on the geometry of the part. Once wrapped in this manner, the multi-layered nodes and the entire part can be cured and/or fused as described herein or by other methods, and the multi-layered nodes can be consolidated

It is also noted that these lattice support structures can be formed using a solid mandrel, having grooves embedded therein for receiving filament when forming the lattice supports structure. Being produced on a mandrel allows the cross supports of the structural unit to be round, triangular or square or any sectional form of these including but not limited to rounding one or more corners. For production, the filaments are wrapped around a break-away mandrel generally conforming to the desired patterns of the members and providing a solid geometric base for the structure during production. Though a secondary wrap, e.g., KEVLAR, may be applied once the structure has been cured or combined with the primary fibers before cure, consolidation of members can be achieved through covering the uncured structure with a bagging system, creating negative pressure over at least the multi-layered nodes, and running it through an autoclave or similar curing cycle. This adds strength through allowing segments of components to be formed from a continuous filament, while also allowing the various strands in a single member to be consolidated during curing.

Turning now to more specific detail regarding consolidation of the multi-layered nodes, it has been recognized that the closer the fibers are held together, the more they act in unison as a single piece rather than a group of fibers. In composites, resin can facilitate holding the fibers in close proximity of each other both in the segments of the cross supports themselves, and at the multi-layered nodes when more than one directional path is being taken by groups of unidirectional fibers are layered. In filament winding systems of the present disclosure, composite tow or tape (or other shaped filaments) can be wound and shaped using a solid mandrel, and then the composite fibers forced together using pressure. Under this pressure, heat can be used to fuse the multi-layered nodes, generating a tightly consolidated multi-layered node. Thus, the multi-layered node is held in place tightly using pressure, and under pressure, the multi-layered node (including the filament or tow material and the resin) can be heat fused or cured, making the multi-layered node more highly compacted and consolidated than other systems in the prior art. Further, by using a rigid mandrel with specifically cut paths for the unidirectional fiber to be laid into, the multi-layered nodes are held tight during the consolidation process. Industry-standard bags, polyurea-based products, or other bagging materials placed over the fibers can act as a pressure medium, pushing the fibers into the grooves of the solid mandrel and removing any voids which may occur by other methods. As a result, high levels of consolidation (90-100% or even 98-100%) can be achieved. In other words, porosity of the consolidated material providing voids and weak spots in the structure are significantly reduced or even virtually eliminated. In short, consolidation control using a rigid mandrel, pressure over the wound filament or fibers, and resin/heat curing provides high levels of consolidation that strengthen the lattice as a whole.

In addition, there are other advantages of the system described herein, namely the ability to manipulate the cross-sectional geometry of the cross sectional shape of the individual cross supports. As a function of the solid mandrel and the silicone, VacuSpray 20, or other similar materials, forcing the fibers into the cut grooves allows for the geometry of the cross supports to be modified in cross section. Any geometry which can be applied to the grooves of the rigid mandrel can be used to shape resulting cross supports and can range from square/rectangular to triangular, half-pipe, or even more creative shapes such as T-shape cross sections. This provides the ability to control or manipulate the moment of inertia of the cross support members. For example, the difference in inertial moments of a flat unit of about 0.005″ thickness and a T-shaped unit of the same amount of material can reach up to and beyond a factor of 200. With the use of a solid mandrel, pressure application, and resin/temperature curing, measurement has shown that geometric tolerances can be kept at less than 0.5%.

The above detailed description describes the disclosure with reference to specific representative embodiments. However, it will be appreciated that various modifications and changes can be made without departing from the scope of the present disclosure as set forth in the appended claims. The detailed description and accompanying drawings are to be regarded as merely illustrative, rather than as restrictive, and all such modifications or changes, if any, are intended to fall within the scope of the present disclosure as described and set forth herein. More specifically, while illustrative representative embodiments of the invention have been described herein, the present invention is not limited to these embodiments, but includes any and all embodiments having modifications, omissions, combinations (e.g., of aspects across various embodiments), adaptations and/or alterations as would be appreciated by those in the art based on the foregoing detailed description. The limitations in the claims are to be interpreted broadly based on the language employed in the claims and not limited to examples described in the foregoing detailed description or during the prosecution of the application, which examples are to be construed as non-exclusive. Also, any steps recited in any method or process claims can be executed in any order and are not limited to the order presented in the claims.

Claims

1. A lattice support structure, comprising a plurality of fiber-based cross supports intersecting one another to form a multi-layered node, said multi-layered node being consolidated within a groove of a rigid mold in the presence of resin, heat, and pressure.

2. The lattice support structure of claim 1, wherein each of said cross supports have a thickness, and wherein said multi-layered node is thinner than the sum of the thickness of each cross support at the multi-layered node.

3. The lattice support structure of claim 1, wherein the multi-layered node comprises multiple layers of all of the cross supports intersecting to form the node.

4. The lattice support structure of claim 1, further comprising a plurality of multi-layered nodes, each multi-layered node formed from a plurality of fiber-based cross supports intersecting one another, at least one of said cross supports being layered at each of the plurality of multi-layered nodes.

5. The lattice support structure of claim 4, wherein the at least one cross support is curved between two multi-layered nodes.

6. The lattice support structure of claim 4, said lattice support structure having a generally cylindrical shape, and comprising at least one helical cross support.

7. The lattice support structure of claim 6, further comprising a second helical cross support.

8. The lattice support structure of claim 7, wherein the helical cross support intersects the second helical cross support to form the multi-layered node.

9. The lattice support structure of claim 8, wherein the helical cross support intersects the second helical cross support to form a plurality of multi-layered nodes.

10. The lattice support structure of claim 6, further comprising a longitudinal cross support that intersects the helical cross support to form the multi-layered node.

11. The lattice support structure of claim 10, wherein the longitudinal cross support intersects the helical cross support to form a plurality of multi-layered nodes.

12. The lattice support structure of claim 6, further comprising a circumferential cross support that intersects the helical cross support to form the multi-layered node.

13. The lattice support structure of claim 1, wherein at least three cross supports intersect at the multi-layered node.

14. The lattice support structure of claim 13, wherein at least three cross supports each include at least two layers at the multi-layered node.

15. The lattice support structure of claim 1, wherein the multi-layered node has increased surface area along a top surface of the lattice support structure compared to a bottom surface of the lattice support structure.

16. The lattice support structure of claim 1, wherein the fiber material includes carbon fiber.

17. The lattice support structure of claim 1, wherein the fiber material includes fiber glass.

18. The lattice support structure of claim 1, wherein the fiber material includes at least one of boron fibers, basalt fibers, or aramid fibers.

19. The lattice support structure of claim 1, wherein the fiber material is composited with a resin.

20. The lattice support structure of claim 1, wherein the rigid mold is a grooved mandrel.

21. A lattice support structure, comprising:

a) a first cross support comprising fiber material;

b) a second cross support comprising a fiber material, said second cross support intersecting the first cross support; and

c) multi-layered nodes located where the first cross support intersects the second cross support, said multi-layered nodes comprising at least two layers of the first cross support separated by a least one layer of the second cross support,

wherein at least one of said first cross support or said second cross support is curved from node to node.

22. The lattice support structure of claim 21, wherein the multi-layered nodes comprise at least two layers of the second cross support separated by a least one layer of the first cross support.

23. The lattice support structure of claim 21, wherein both the first cross support and the second cross support are curved from node to node.

24. The lattice support structure of claim 21, wherein the first cross support is not curved.

25. The lattice support structure of claim 21, wherein the second cross support is not curved.

26. The lattice support structure of claim 21, further comprising a third cross support comprising a fiber material.

27. The lattice support structure of claim 26, wherein the third cross support intersects the first cross support.

28. The lattice support structure of claim 26, wherein the third cross support intersects the second cross support.

29. The lattice support structure of claim 26, wherein the first cross support, the second cross support, and the third cross support each intersect at a common multi-layered node.

30. The lattice support structure of claim 29, wherein the common multi-layered node includes multiple layers of the first cross support, the second cross support, and the third cross support, each layer of each cross support being separated by a layer of another cross support.

31. The lattice support structure of claim 26, wherein the third cross support is curved.

32. The lattice support structure of claim 26, wherein at least one of the cross supports is longitudinally oriented, and at least two of the cross supports are helically oriented.

33. The lattice support structure of claim 26, wherein all three cross supports are helically oriented.

34. The lattice support structure of claim 26, wherein at least one of the cross supports is circumferentially oriented.

35. The lattice support structure of claim 21, said lattice support structure having a generally cylindrical shape, and comprising a plurality of helical cross supports and a plurality of longitudinal cross supports.

36. The lattice support structure of claim 35, wherein the longitudinal lattice support structures are not symmetrically spaced around a circumference of the cylinder.

37. The lattice support structure of claim 35, wherein at least two helical lattice support structures do not have the same number of twists around the cylinder as one another.

38. The lattice support structure of claim 35, wherein the multi-layered node has increased surface area along the outermost perimeter of the cylinder compared to the innermost surface of the cylinder.

39. The lattice support structure of claim 21, wherein the multi-layered nodes are consolidated by resin, heat, and pressure.

40. The lattice support structure of claim 39, wherein at least a portion of the multi-layered node is placed under pressure against a rigid mold while undergoing heat and resin curing.

41. The lattice support structure of claim 21, wherein the fiber material includes carbon fiber.

42. The lattice support structure of claim 21, wherein the fiber material includes fiber glass.

43. The lattice support structure of claim 21, wherein the fiber material includes at least one of boron fibers, basalt fibers, or aramid fibers.

44. The lattice support structure of claim 21, wherein the fiber material is composited with a resin.

45. The lattice support structure of claim 44, wherein the resin is epoxy, BMI, or phenolic resin.