Composite geometric support structures and associated methods and systems

Abstract

Geometrically versatile composite lattice support structure having a seamless three-dimensional configuration are disclosed and described. The lattice support structure is created by forming two or more cross supports, such as helical, longitudinal, circumferential and/or lateral cross supports, which intersect to form a plurality of multi-layered nodes. The lattice support structure may be designed without any protrusions extending outward from the overall geometry, thus enabling efficient tooling, and thus enabling ease of mass production. The lattice support structure may comprise a completely circumferentially closed geometry, such as a cylinder, ellipse, airfoil, etc. The method for fabricating the lattice support structure comprises laying up a fiber material, in the presence of resin, within rigid channels of a rigid mold, thus creating a green, uncured three-dimensional geometry of unconsolidated cross supports and multi-layered nodes where these intersect. Subjecting these to a curing system functions to consolidate the cross supports and multi-layered nodes to produce the composite lattice support structure.

What is claimed and desired to be secured by Letters Patent is: 
     
         1 . A lattice support structure, comprising a plurality of fiber-based cross supports, the fiber-based cross supports having individual fibers layered in an off-set configuration and intersecting one another to form a multi-layered node, said multi-layered node being consolidated within a groove of a 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 , said lattice support structure having a generally cylindrical shape, and comprising at least one helical cross support. 
     
     
         6 . The lattice support structure of  claim 5 , further comprising a longitudinal cross support that intersects the helical cross support to form the multi-layered node. 
     
     
         7 . The lattice support structure of  claim 5 , further comprising a circumferential cross support that intersects the helical cross support to form the multi-layered node. 
     
     
         8 . The lattice support structure of  claim 1 , wherein at least three cross supports intersect at the multi-layered node and wherein at least three cross supports each include at least two layers at the multi-layered node. 
     
     
         9 . 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. 
     
     
         10 . The lattice support structure of  claim 1 , wherein the fiber material includes carbon fiber, fiber glass, boron fibers, basalt fibers, or aramid fibers and wherein the fiber material is composited with a resin. 
     
     
         11 . 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 layered in an off-set configuration,   wherein at least one of said first cross support or said second cross support is curved from node to node.   
     
     
         12 . The lattice support structure of  claim 11 , 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. 
     
     
         13 . The lattice support structure of  claim 11 , wherein both the first cross support and the second cross support are curved from node to node. 
     
     
         14 . The lattice support structure of  claim 11 , further comprising a third cross support comprising a fiber material. 
     
     
         15 . The lattice support structure of  claim 14 , wherein the first cross support, the second cross support, and the third cross support each intersect at a common multi-layered node and 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. 
     
     
         16 . The lattice support structure of  claim 11 , said lattice support structure having a generally cylindrical shape, and comprising a plurality of helical cross supports and a plurality of longitudinal cross supports. 
     
     
         17 . The lattice support structure of  claim 16 , wherein the longitudinal lattice support structures are not symmetrically spaced around a circumference of the cylinder. 
     
     
         18 . The lattice support structure of  claim 16 , wherein at least two helical lattice support structures do not have the same number of twists around the cylinder as one another. 
     
     
         19 . The lattice support structure of  claim 16 , wherein the multi-layered node has increased surface area along the outermost perimeter of the cylinder compared to the innermost surface of the cylinder. 
     
     
         20 . A system for forming complex three-dimensional composite lattice support structures, said system comprising:
 a mold having a plurality of channels, at least some of said plurality of channels intersecting at strategic locations;   a lay-up of fiber material, in the presence of a resin, within said channels, said fiber material comprising fiber filaments that are layered with one another and that intersect at said strategic locations; and   a curing system for consolidating said lay-up to form a plurality of cross supports and multi-layered nodes, wherein the multi-layered nodes are flattened in shape.