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.

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, wherein said multi-layered node comprises at least two layers of the cross supports. 
     
     
         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 . (canceled) 
     
     
         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 at 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 - 45 . (canceled)