FLEX SHAFT
A flex shaft for a motor may comprise a hollow tubular member with first and second connector ends. In some embodiments, a thickness or wall thickness of the tubular member may be selected in accordance with a desired strength or torque the flex shaft must be capable of handling. In some embodiments, a plurality of openings may be provided in the wall of the tubular member to provide a desired level of flexibility. The plurality of openings may be arranged or patterned in numerous ways discussed herein. The flex shaft allows a shorter overall length to be used than for a conventional solid shaft.
1 . A flexible shaft comprising:
a hollow tubular, wherein the hollow tubular provides a first connector end and a second connector end; and
a plurality of openings in a wall of the hollow tubular, wherein the plurality of openings span a distance between the first and the second connector ends.
2 . The shaft of claim 1 , wherein the plurality of openings are circular, ovular, square, rectangular, or a combination thereof.
3 . The shaft of claim 1 , wherein the plurality of openings are arranged into one or more sets running along the length of the hollow tubular.
4 . The shaft of claim 3 , wherein the plurality of openings in each set are spaced apart by a set distance.
5 . The shaft of claim 3 , wherein the one or more sets are angularly spaced apart from each other relative to an axis through a center of the hollow tubular.
6 . The shaft of claim 5 , wherein the one or more sets are angularly spaced apart from each other with equidistant angular spacing.
7 . The shaft of claim 6 , wherein the plurality of openings in each set are spaced apart by a set distance.
8 . The shaft of claim 6 , wherein the one or more sets are angularly spaced apart by 90°.
9 . The shaft of claim 6 , wherein the openings of adjacent sets of the one or more sets are offset relative to a latitude of the hollow tubular.
10 . The shaft of claim 6 , wherein the openings span ≧90° of a circumference of the hollow tubular and ≦180° of the circumference of the hollow tubular.
11 . The shaft of claim 10 , wherein the openings of adjacent sets of the one or more sets are offset relative to a latitude of the hollow tubular.
12 . The shaft of claim 3 , wherein the sets are arranged in a spiral pattern.
13 . The shaft of claim 1 , wherein the first connector end attaches to a rotor of a motor.
14 . The shaft of claim 1 , wherein the second connector end attaches to a bearing mandrel.
15 . A method for forming a flexible shaft, the method comprising:
forming a hollow tubular, wherein the hollow tubular provides a first connector end and a second connector end; and
forming a plurality of openings in a wall of the hollow tubular, wherein the plurality of openings span a distance between the first and the second connector ends.
16 . The method of claim 15 , wherein the plurality of openings are arranged into one or more sets running along the length of the hollow tubular.
17 . The method of claim 15 , wherein the one or more sets are angularly spaced apart from each other relative to an axis through a center of the hollow tubular, and the openings of adjacent sets of the one or more sets are offset relative to a latitude of the hollow tubular.
18 . The method of claim 16 , wherein openings in each set are spaced apart by a set distance, and the one or more sets are angularly spaced apart with an equidistant angular spacing.
19 . The method of claim 16 , wherein the one or more sets are angularly spaced apart by 90°, and the openings span ≧90° of a circumference of the hollow tubular and ≦180° of the circumference of the hollow tubular.
20 . The method of claim 15 , wherein the sets are arranged in a spiral pattern.